U.S. patent application number 11/681434 was filed with the patent office on 2007-09-06 for top load cartoner.
This patent application is currently assigned to R.A. Jones & Co. Inc.. Invention is credited to Robert James Burkhardt, Christopher Michael George, Anthony B. Salvato, Jeffrey D. Wintring.
Application Number | 20070204567 11/681434 |
Document ID | / |
Family ID | 38470271 |
Filed Date | 2007-09-06 |
United States Patent
Application |
20070204567 |
Kind Code |
A1 |
Wintring; Jeffrey D. ; et
al. |
September 6, 2007 |
TOP LOAD CARTONER
Abstract
A cartoning method including the steps of: feeding blanks from a
single magazine through a single blank feeder in a first direction;
forming an array of at least two blanks from the fed blanks and
thereafter transporting the array for forming, loading and closing
via respective robot kinetics of at least two axis motion. Carton
blanks and cartons travel through a path. Robots below the path
transport the cartons. Robots above the path facilitate carton
forming, loading and closing. Methods and apparatus are
disclosed.
Inventors: |
Wintring; Jeffrey D.;
(Florence, KY) ; Burkhardt; Robert James; (Fort
Mitchell, KY) ; George; Christopher Michael;
(Cincinnati, OH) ; Salvato; Anthony B.;
(Cincinnati, OH) |
Correspondence
Address: |
WOOD, HERRON & EVANS, LLP
2700 CAREW TOWER
441 VINE STREET
CINCINNATI
OH
45202
US
|
Assignee: |
R.A. Jones & Co. Inc.
2701 Crescent Springs Road
Covington
KY
41017
|
Family ID: |
38470271 |
Appl. No.: |
11/681434 |
Filed: |
March 2, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60799111 |
May 10, 2006 |
|
|
|
60854023 |
Oct 24, 2006 |
|
|
|
60779111 |
Mar 3, 2006 |
|
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Current U.S.
Class: |
53/452 ;
53/564 |
Current CPC
Class: |
B65B 5/024 20130101 |
Class at
Publication: |
053/452 ;
053/564 |
International
Class: |
B65B 43/26 20060101
B65B043/26 |
Claims
1. A cartoning method including the steps of: feeding blanks from a
single magazine through a single blank feeder in a first direction;
and forming an array of at least two blanks of predetermined number
from said blanks.
2. A method as in claim 1 including the step of: applying glue
sequentially to cartons being fed from said feeder prior to the
formation of said array.
3. A method as in claim 1 including the step of: applying glue to
said fed blanks after forming them into said array.
4. A method as in claim 1 including the further step of: moving
said array in a second direction perpendicular to the first
direction in which carton blanks are fed from said feeder.
5. A method as in claim 1 including transporting said array to a
carton forming station and there at least partially forming cartons
from said blanks in said array.
6. A method as in claim 1 including the further steps of:
transporting cartons from said carton forming station to a loading
station and there loading items into said cartons; transporting
loaded cartons to a closing station and closing loading cartons;
and discharging cartons.
7. A method as in claim 6 including transporting cartons from said
carton forming station to said loading station by a robot having at
least a two-axis motion.
8. A method as in claim 6 including transporting cartons from said
loading station to said closing station by a robot having at least
a two-axis motion.
9. A method of cartoning, including the forming, transporting and
loading of cartons in selected carton arrays of two or more
cartons, and including the steps of: feeding carton blanks onto a
feed conveyor at a single infeed location from a single carton
blank feeder; and forming an array of carton blanks on a feed
conveyor by said feeding.
10. A method of handling carton blanks and including the steps of:
feeding carton blanks sequentially from a single infeed point;
applying glue sequentially to said fed blanks; forming, at an array
station, an array of blanks, having glue applied thereto; and
transferring said array away from said array station.
11. A method as in claim 9 wherein the steps of feeding and
applying glue to said blanks includes moving said blanks in the
same direction during said feeding and said glue applying.
12. A method of cartoning wherein a plurality of operations are
carried out on cartons and including the steps of conducting some
of said operations in a continuous motion and some in an
intermittent motion and wherein said motions are decoupled one from
the other.
13. A method of cartoning wherein products are loaded into cartons
and including the steps of: forming cartons; transporting formed
cartons to a loading station; loading cartons; and transporting
cartons from said loading station; wherein at least one of said
steps is carried out in continuous motion and another of said steps
is carried out in intermittent motion and wherein said respective
motions are decoupled one from the other.
14. A method as in claim 13 wherein said forming, transporting and
loading steps are all carried out by robots having at least two
axes of motion and including the further step of selectively
raising and lowering cartons with said robots during said
cartoning.
15. A method as in claim 13 including: engaging such cartons in
end-of-arm tooling on a robot; and performing a carton manipulating
operation on cartons while said cartons are engaged by said
tooling.
16. Apparatus for handling carton blanks, said apparatus including:
a blank feeder defining a single infeed; a blank conveyor oriented
to receive fed blanks from said single infeed and for transferring
said blanks to a glue station; glue apparatus oriented to apply
glue to blanks transported there-past; and an array orienting
station downstream of said glue apparatus.
17. Apparatus as in claim 16 and further including a blank
receiving apparatus receiving fed blanks sequentially from said
infeed and transferring fed blanks to said conveyor.
18. Apparatus as in claim 16 wherein said blanks are fed
sequentially onto said blank conveyor in a first direction, said
conveyor oriented for moving said blanks in a single direction from
said infeed past said glue apparatus.
19. Apparatus as in claim 18 including transfer apparatus for
moving an array of said blanks, downstream of said glue apparatus,
in a second direction, perpendicular to said first direction,
toward a carton forming station.
20. A cartoner comprising: a former robot; a former-to-loader
transport robot; a loader robot; and a loader-to-closer transport
robot said robots operationally interconnected to form, transport,
load and further transport loaded cartons.
21. A cartoner as in claim 20 wherein said former and loader robots
are oriented above a path of movement of said cartons and said
respective transport robots are oriented below said path.
22. A cartoner as in claim 21 further including end-of-arm tooling
respectively carried by respective ones of said robots.
23. A cartoner as in claim 22 further including at least two sets
of end-of-arm tooling, each set facilitating loading of cartons
oriented at a different pitch from cartons whose loading is
facilitated by the other set.
24. Cartoning apparatus comprising: a single magazine; a feeder for
feeding blanks received from said single magazine in a first
direction; a conveyor for receiving at least two blanks defining an
array of blanks; and apparatus having motion in at least two axes
for moving said array from said conveyor toward a carton forming
apparatus.
25. Apparatus as in claim 24 further including a robot for
transporting an array of cartons from a carton former station to a
carton loading station.
26. Apparatus as in claim 25 wherein said robot is disposed beneath
a path in which said array of cartons passes and said apparatus for
moving said array from said conveyor toward a carton forming
apparatus is disposed above said path.
27. Apparatus as in claim 25 further including two robots for
transporting an array of cartons from a carton former station to a
carton loading station.
28. Apparatus as in claim 24 further including a robot for
transporting an array of cartons from a carton loading station to a
carton closing station.
29. Apparatus as in claim 28 further including a robot for loading
items into said array of cartons and wherein said robot for
transporting is disposed beneath a path in which said array of
cartons moves and said robot for loading items is disposed above
said path.
30. Apparatus as in claim 27 further including two robots for
transporting an array of cartons from a carton loading station to a
carton closing station.
Description
PRIORITY CLAIM
[0001] Applicant claims the benefit of the filing date of Mar. 3,
2006 of U.S. provisional patent application Ser. No. 60/779,111 and
of the filing date of Oct. 24, 2006 of U.S. provisional patent
application Ser. No. 60/854,023, both of the same title as this
utility application and both herewith expressly incorporated herein
by reference.
FIELD OF THE INVENTION
[0002] This invention relates to cartoners and more particularly to
cartoners capable of loading items into cartons or trays through
the carton or tray top, rather than from its end or side.
BACKGROUND OF THE INVENTION
[0003] Traditional cartoners are generally designed to load cartons
from the end or side, where items are pushed into an erected carton
and thereafter side or end flaps are glued and closed to
finish.
[0004] There have been several attempts at top loading cartons or
trays with items. In these devices, portions of a flat carton or
tray blank, are glued up or a lock mechanism is used to form an
open carton or tray which is then loaded from the top. Alternately,
the blank is partially formed around an item or group of items
placed on the blank, such as in a wraparound process.
[0005] Presently, the industry desires to accomplish a variety of
packaging formats for a variety of products, and to do so on a
single, relative low cost cartoner, with minimal change parts or
modules and changeover downtime for different package
configurations or size. In this regard, it will be appreciated that
packaging machines, such as cartoners, typically operate either
continuously or intermittently. That is, the equipment continuously
moves items and packages or cartons through a process where they
are combined, or the equipment operates intermittently to this
end.
[0006] Advantages of an intermittent cartoner are typically lower
cost, smaller machine footprint and accommodation of many load
building and load configuration options. Advantages of a continuous
motion cartoner, among others, are high speeds and operational
benefits in product loading. The choice of one or the other of
these operating processes is typically made at the expense of
losing one or more advantages of the other.
[0007] Accordingly, one objective of the invention has been to
provide a top loading carton apparatus capable of loading items
into a variety of package or carton formats and utilizing
advantages of both continuous and intermittent cartoning
processes.
[0008] In another aspect of the cartoning process, it will be
appreciated that typical cartoners of the past traditionally erect
and convey cartons on a fixed pitch spacing. For example, cartons
are conveyed by chain-driven lugs at fixed distances with respect
to each other throughout the carton erecting, loading, gluing,
closing and discharge operations. Such fixed pitch equipment can be
adjusted to different pitch, but this requires downtime, not only
in the adjustment of carton conveying lugs but in changeover and
adjustment of associated equipment such as loaders, gluers, closers
and the like.
[0009] Accordingly, it is another objective of the invention to
provide a cartoner which is pitchless, that is a cartoner which can
handle a variety of blank formats and sizes without regard to pitch
(or spacing therebetween) and being easily programmed and adjusted
for a wide variety of carton types and spacing, and with minimal
downtime and changeover parts.
[0010] A further objective of the invention has been to provide an
improved top loading cartoner.
SUMMARY OF THE INVENTION
[0011] To these ends, the invention contemplates a cartoner with a
unique combination of elements and functions which facilitate the
mixing and matching of both continuous and intermittent operations
wherever in the process these operations are most beneficial or
advantageous. Such operations are carried out sequentially or
simultaneously in any desired mix and independently of the nature
of an operation in another part of the cartoning process. The
invention, in one aspect, contemplates the use of tooling for
holding cartons or trays while continuous or intermittent processes
as desired are carried out on them. As an example, at least two
separately programmable transport robots handle cartons or trays
with intermediate tooling. And "Z" or vertical axis motion can be
used for particular carton processes.
[0012] More particularly, the invention contemplates, in at least
one embodiment, a cartoner having a single carton blank feeder (as
opposed to multiple feeders) preferably fed by a single blank
magazine and for depositing through a single feed point one or a
group of cartons on a feeder conveyor. The interaction of the
timing of the blank feeder and of the feeder conveyor sets the
spacing or pitch between carton blanks on the feed conveyor.
[0013] A robot disposed above the cartons, and provided, for
example, with vacuum tooling, picks up the cartons and in this
embodiment moves them through a glue area (as required), and a die
area where the blanks are formed into trays or cartons with open
tops.
[0014] Another robot, disposed beneath a carton path is provided
with tooling to then receive and transport a batch of the formed
cartons from the forming area to a load area. During this
transport, the carton pitch can, if desired, be closed up by the
robot with the cartons moved closer together.
[0015] The batch of formed cartons is loaded through open tops by
yet a third robot. Thereafter, the cartons are moved to a glue
and/or closing station by yet a fourth robot from where the
completed trays or cartons are discharged.
[0016] In summary in one embodiment, the feeding and forming steps
are carried out continuously, in single stream form with arrays of
blanks, the loading is performed intermittently and the gluing and
closing continuously, with carton pitch varying as desired during
the process. Adjunct tooling, elements and the like can be used to
operate on or with the cartons or trays as they are held within the
end of arm tooling of the robots. For example, pitch of the cartons
can be changed.
[0017] The invention is facilitated by a unique combination of
robots disposed both above and below the carton path, each provided
with tooling to handle, form or load cartons or trays through
segments of the operation.
[0018] It will be appreciated that the operation on the blanks, and
the cartons or trays formed from them, are carried out in the
various stages of the carton in either continuous or intermittent
fashion, depending on which format is most advantageous for the
particular operation, and quite independent of the operational
format used in other stages of the cartoning process. Thus smaller
footprint, product loading and carton specific operations are
provided and enhanced, producing a cartoning operation with
benefits of both continuous and intermittent motion, and all in a
pitchless or pitch varying process. The unique combination of
robots oriented for transport below the cartons, combined with
robots oriented above the cartons for forming and loading, produce
unique and significant results in a top loading cartoner of the
invention.
[0019] In another embodiment, carton blanks are fed from a single
magazine through a single feeder, but are glued as, or just after,
they are fed so that an array of glued cartons is provided and
there is no need for another glue area or station operating on the
array of blanks as in the above embodiment.
[0020] It will be appreciated that there is no need in the
invention for multiple carton feeders or feeder magazines (even
though multiple feeders could be used), thus leaving open a side of
the cartoner where such multiple units would otherwise block
access.
[0021] Use of two or more lower robots beneath the cartoner for
carton transport can accommodate whole or half tooling with
sufficient clearance or programming control so tooling interference
at higher speeds are avoided.
[0022] Moreover, it will be appreciated the invention includes the
process of forming an array of blanks from a single magazine and
feeding blanks into an array through a single infeed point. Also, a
process according to the invention includes transporting the blanks
between forming and loading stations and between loading and
closing stations using a two-axis motion or robotic mechanism.
[0023] These and other objectives and advantages of the invention
will be readily appreciated from the foregoing, and from the
following written description and drawings, in which:
Brief Description of the Drawings
[0024] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate embodiments of
the invention and, together with a general description of the
invention given above, and the detailed description given below,
serve to explain the invention.
[0025] FIG. 1 is an illustrative perspective view of one cartoner
embodiment according to the invention;
[0026] FIG. 2 is a diagrammatic flow chart of the operation of the
cartoner in FIG. 1;
[0027] FIGS. 3A and 3B are illustrative views of a variety of one
form of carton or tray or sleeve sizes and shapes which can be
formed and loaded on the cartoners of FIGS. 1-2;
[0028] FIG. 4A is an illustrative view of one robot assembly
operating below the carton path of the cartoner in FIGS. 1-2;
[0029] FIG. 4B is an end elevational view taken along lines 4B-4B
of FIG. 4A;
[0030] FIG. 5 is a perspective view of a cartoner according to the
invention illustrating use of an under carton path robot of FIGS.
4A and 4B in the carton forming, loading and closing area of the
cartoner;
[0031] FIG. 6 is a perspective view of an overhead robot of the
type used in forming or in loading of cartons according to the
invention;
[0032] FIG. 7 is a perspective illustration of a carton blank
feeder for feeding cartons at selected pitch for forming and
loading according to the invention;
[0033] FIG. 8 is a perspective illustration of the loading area of
the invention as in FIGS. 1-2 but illustrating an alternate
orientation of two robots in the loading area, each separately
programmable for performing desired loading functions;
[0034] FIGS. 9-20 are respective perspective views illustrating a
sequence of operations or features of a cartoner embodiment
according to the invention;
[0035] FIG. 21 is a perspective view illustrating an alternate
embodiment of the invention where four transport robots are used to
produce a higher product through-put speed;
[0036] FIGS. 22-28 are respective perspective views illustrating a
sequence of operations of another cartoner embodiment according to
the invention, particularly adapted to handling product containing
sleeve-type packages;
[0037] FIG. 29 is an illustrative perspective view of an alternate
cartoner embodiment according to the invention, with like parts to
the embodiment of FIG. 1 numbered similarly;
[0038] FIG. 30 is a diagrammatic flow chart of the operation of the
cartoner of FIG. 29;
[0039] FIGS. 31-38 are illustrative drawings showing features of
the alternative embodiment features of FIGS. 29 and 30 and are
further described;
[0040] FIG. 31 is a view looking upstream and shows the carton
blank magazine(with feed omitted for clarity), with the reciprocal
suction cup platform for raising to receive fed blanks and for
lowering to place them on vacuum belts in the foreground of the
drawing;
[0041] FIG. 32 is a view looking upstream and illustrates the
carton magazine and the downstream glue guns;
[0042] FIG. 33 is a view looking downstream, showing the glue guns,
the blank receiving area on the vacuum belts and the former
robot;
[0043] FIG. 34 is a view looking across the vacuum belts and shows
a fed but yet unglued blank;
[0044] FIG. 35 is a view showing a second sequentially fed blank,
with a first downstream blank approaching the glue station from
left-to-right;
[0045] FIG. 36 is a view similar to FIG. 35 but showing a third
sequentially fed blank with the first downstream blank having
passed the glue station and the second blank approaching the glue
station;
[0046] FIG. 37 is a view showing an array of three glued blanks,
ready for picking by a robot for transfer to former tooling;
and
[0047] FIG. 38 is a view showing the array of three glued blanks as
in FIG. 37 but from the opposite direction of FIG. 40 and also
shows the former tooling area to which the array will be
transferred.
Detailed Description
[0048] Turning to the drawings, and particularly FIGS. 1-3B, it
will be appreciated that the invention in one embodiment is capable
of top loading a variety of open-top cartons or trays 10 as
illustratively depicted in different sizes in FIGS. 3A and 3B.
While cartons 10 are specifically shown, it will be appreciated
that trays, sleeves and other forms of packaging can be handled
according to the invention.
[0049] FIG. 3A illustrates a variety of the flat carton blanks 10
in open or developed configuration while FIG. 3B illustrates the
varied open top cartons 10 of FIG. 3A but in erected configuration,
with open top and side flaps, ready for loading of items through
the open tops shown. Various cartons are depicted in FIGS. 3A and
3B in overlaid form for clarity to illustrate the variety of sizes
of one carton format which can be handled in the cartoner of the
invention. Other carton, tray and sleeve formats can be handled as
well and reference to cartons herein is not meant to limit the
scope of the invention.
[0050] FIGS. 1-2 illustrate diagrammatically features (FIGS. 1-2)
and the operational process (FIG. 2) of one embodiment of the
invention as a top loading cartoner 14. The invention is clearly
understood by the following description of a sequence of operation
of the invention and of its features.
[0051] The overall process and apparatus of this embodiment are
best seen in FIGS. 1-2, however, reference is also to the sequence
illustrated in FIGS. 9-21 and to FIGS. 22-28 as appropriate. A
reciprocating feeder pick-arm pulls a single blank B from the
horizontal magazine 18 and positions the blank B on the feed
conveyors 19 in a feed conveyor area.
[0052] As the reciprocating feed arm 17 returns to get the next
blank B, the feed conveyor 19 advances in a first direction forward
one station to prepare to receive the next blank B.
[0053] The process continues until the count of blanks B for the
machine set-up is achieved (i.e., usually 2 to 6 blanks), these
blanks forming an "array" of blanks. The feed conveyor 19
incorporates additional features such as vacuum hold down, that
provide hold-down and positioning capability for the blanks. Four
blanks in an array are shown for clarity here.
[0054] As used herein, an "array" of blanks describes a group of
two or more blanks on which operations can be performed
simultaneously. In other embodiments, an "array" could simply
describe a blank group.
[0055] Once the last blank B (the fourth blank B of FIGS. 1 and 2)
is received into the feed conveyor area and moved into position,
the overhead Former Robot 22 engages all of the arrayed blanks
simultaneously with its vacuum tooling 23, which may be of any
suitable construction.
[0056] Having received a signal that vacuum has been achieved at
each blank B, the Former Robot raises vertically a short distance
to disengage from the feed conveyor area 19 and then begins a
horizontal move in the direction of arrow 54 perpendicular to the
longitudinal flow of the original blank flow stream in the first
direction (see the "Position" to "Glue" step of FIG. 2).
[0057] Having moved away from the feed conveyor 19, the Former
Robot passes the array of four carton blanks being carried in a
second perpendicular direction over a stationary glue gun region 26
(when needed). Multiple glue guns shoot upward to apply glue at the
appropriate positions on the blanks B. It is understood glue may or
may not be required at this time.
[0058] Continuing the blank motion past the glue gun region 26 in
the second direction, the Former Robot carries the array of four
carton blanks B into position over the top of the forming or
closing die area 28, comprising a plurality of closing dies (not
shown in detail).
[0059] The Former Robot 22 then plunges the array of carton blanks
B preferably downward through individual forming dies to produce
the bottom shape of cartons. Depending on the machine set-up, the
Former Robot will then either release the open top cartons C at the
bottom of the Former Robot stroke, as it hands-off to the below
mounted Former-to-Loader Transport Robot 30, or alternately return
upward back out the top of the forming dies with the cartons C. If
the second approach is used, the Former Robot then moves
horizontally an additional distance and then lowers to make the
hand-off of cartons to the below mounted Former-to-Loader Transport
Robot 30.
[0060] Having successfully made the hand-off, the Former Robot 22
returns to the feed conveyor area 19 to repeat its cycle while the
Former-to-Loader Transport Robot 30 moves horizontally
(perpendicular to the Former Robot flow, see FIG. 2) toward the
loading area 32.
[0061] When the Former-to-Loader Transport Robot 30 arrives in the
loading area 32, it stops at the handoff station 33 that engages
the cartons C via vacuum to hold the carton positions for the
loading process and then subsequent pick-up by the
Loader-to-Closing Transport Robot 36.
[0062] Once the handoff station 33 has engaged the carton array,
the Former-to-Loader Transport Robot 30 lowers slightly downward
away from the carton array and then returns back to repeat its
cycle. While the Former-to-Loader Transport Robot 30 is returning,
the overhead Loader Robot 38 can begin the loading process at the
loading area. Various types of suitable robots can be utilized in
the loading area, such as an: Overhead Two-axis Robot, SCARA,
Six-axis, etc. or any other suitable Robot kinematic can be used.
As well, any suitable Robots combined or oriented as described
herein may be found useful in the invention.
[0063] Having previously picked up the appropriate quantity and
configuration of products (not shown) from a product infeed system
40 with its tooling, the Loading Robot 38 is ready to insert the
product into the cartons C once they are engaged by the handoff
station 33. Depending on the machine set-up, product requirements,
and product infeed design, the Loader Robot 38 can pick-up and
place multiple cartons' worth of product during each move or
alternately fill each of the cartons C individually (even if an
array of cartons is being processed through other parts of the
machine).
[0064] While the loading process is taking place and after the
Former-to-Loader Transport Robot 30 disengaged and has started to
move away from the handoff station, the Loader-to-Closing Transport
Robot 36 can move into position under the carton array in the
handoff station 33 and engage the cartons C with its tooling.
[0065] When the loading process is complete, the Loader-to-Closing
Transport Robot 36 can begin to move horizontally away from the
handoff station 33 toward the closing and discharge section 42.
[0066] Enroute to the closing area 42 of the machine 14, the
Loader-to-Closing Transport Robot 36 carries the carton array past
an optional gluing station 44 provided with glue guns (not shown)
for glue application to the carton top flaps F. Prior to aligning
with the glue guns, the cartons C individually engage fixed
guide-work (not shown) that bend the flaps F into proper position
to receive the glue.
[0067] After the glue is applied, the Loader-to-Closing Transport
Robot 36, having never stopped its horizontal motion, continues to
carry the carton array past fixed guide-work (not shown) that
further moves the flaps into position for final closing.
[0068] Having arrived at the closing section 42, the
Loader-to-Closing Transport Robot 36 stops its horizontal motion
and then moves vertically, pushing the cartons upward through
individual stationary dies (not shown). The stationary dies push
the carton flaps closed and compress the glue, producing the
completed cartons at the top of the Loader-to-Closing Transport
Robot up-stroke.
[0069] The Loader-to-Closing Transport Robot 36 tooling releases
its hold on the cartons and allows a cross-pusher (not shown)of any
suitable construction, working perpendicular to the
Loader-to-Closing Transport Robot 36 flow, to move the carton array
horizontally onto a discharge conveyor (not shown) that carries the
cartons out of the machine 14 perpendicular to the flow of the
cross-pusher, i.e. in the direction of the machine flow MF or
alternately perpendicular thereto.
[0070] The Loader-to-Closing Transport Robot 36 retracts downward
after the cross-pusher's initial actuation and returns to the
handoff station 33 at the appropriate time to repeat its cycle.
[0071] With reference to FIG. 2, it will be appreciated that
various steps and operations of this embodiment of the invention
are represented in the flowchart, and numbers corresponding to the
Robots described have been illustratively provided to the
appropriate steps in the chart of FIG. 2. In particular, initial
array handling and carton forming is facilitated by the Former
Robot 22. Carton array transport is facilitated by Former-to-Loader
Transport Robot 30, carton loading is facilitated by Loader Robot
38 and carton transport from loading to discharge is facilitated by
Loader-to-Closing Robot 36.
[0072] It will be appreciated that the flow steps illustrated in
FIG. 2 correspond in direction with the top plan view of cartoner
14 showing the flow of cartons and carton arrays.
[0073] It will be further appreciated that Robots 22 and 38 are
oriented generally above the plane of carton movement through
cartoner 14, while the respective transport robots are oriented
below the plan of carton movement through cartoner 14. Each may be
respectively provided not only with X-Y translation, but vertical
or "Z-axis" translation as well.
[0074] Various features of the invention are shown further in FIGS.
4A through FIG. 8. In FIG. 4A, a representative robot 30, 36 is
shown having a head 48 to which can be mounted appropriate
end-of-arm tooling for handling the respective blanks and cartons
for transport. Robots 30, 36 are respectively oriented beneath the
plane of carton movement, and are preferably offset (see FIG. 1)
for handling cartons as described above. Appropriate tooling is of
suitable configuration such that the respective paths in which the
tooling moves are sufficiently separate to accommodate desired
machine speed without tooling interference from one robot=s tooling
with that of another robot.
[0075] FIG. 5 illustrates the parallel orientation of two transport
robots 30, 36 from the rear side of cartoner 14 where the machine
flow is to the left. See also FIG. 20 in this regard, viewed from
the front side of the machine.
[0076] FIG. 6 illustratively depicts overhead robots such as Former
Robot 22 and Loader Robot 38. These may be mounted to appropriate
stationary or even moveable frames as desired. Each has a head 54
on which can be secured the appropriate tooling to handle blanks B
and cartons C respectively (Robot 22) on the appropriate products
for loading (Robot 38). It will be appreciated that such tooling on
Robot 22 can accommodate the number of blanks in an array, or a
smaller number.
[0077] FIG. 7 illustrates the carton blank feed operation with a
single horizontal blank feed magazine 18 illustratively depicted at
18 and feeding flat blanks to feed or picker 17 which lays
individual blanks one at a time onto feed conveyors 19 (not shown
in FIG. 7). Any suitable carton magazine and blank feeder can be
utilized and it will be appreciated that only one is required. The
blanks are depicted in arrays 50, 51 while at least partially
formed cartons C are in array 52. Arrow 54 illustrates the
direction of movement of array 50-52 as also illustrated in FIGS. 1
and 2. The arrays can be any practical number of cartons, set in
count by the feeder 17.
[0078] FIG. 8 illustrates an alternate loading embodiment wherein
overhead Robots 38a and 39b are used for loading products into
cartons. It will be appreciated that one Robot 38a (for example)
can be used for loading. Two or more Robots 38a, 38b can be used to
provide varied loading functions. In such a case, one Robot 38a in
the loading area can be a two-axis robot, while robot 38b could be
a four-axis robot, for example. Other combinations of robotic
kinematics could be used.
[0079] It will be appreciated from FIGS. 1 and 5, for example, that
the cartons in an array 52 can be repositioned with respect to each
other so as to expand or, as shown, close up the spacing between
cartons. Thus, the pitch of the cartons can be changed by any
suitable mechanisms during the forming, loading and closing
processes to accommodate and provide significant flexibility in the
cartoning process. As perhaps best seen in FIG.1, the carton pitch
has been closed up or shortened in the load area 66 where the
carton C can be loaded with product through other open tops on an
intermittent basis, without constraining the continuous motion of
blanks or cartons at the feed area, or in the discharge area. This
ability to operate on a pitchless basis and to use both continuous
and intermittent motion in the same cartoning line provides unique
advantages as mentioned above. Tooling, change out, end of arm
tooling, end effectors or any other suit mechanisms can be used to
facilitate these carton spacing changes as described.
[0080] FIGS. 9-20 illustrate a sequence of carton handling for one
embodiment of the invention, and consistent with the foregoing
description.
[0081] In FIG. 9, open top cartons C-1, C-2 have been handed off at
forming station 32 to an end-of-arm tool 60 mounted on Former to
Loader Transport Robot 30. Tooling 60 is any suitable tooling
capable of handling and transporting cartons C-1, C-2 (just two
cartons here are shown for clarity; the number can be one or more
as practicable). Additional end-of-arm tooling 62 is mounted on the
Loader-to Closing Transport Robot 36 for receiving cartons C-1, C-2
from tooling 60.
[0082] Tooling 60 defines carton positions 69, 70 in this
embodiment, while tooling 62 defines carton positions 71, 72
thereon.
[0083] Also illustrated in FIG. 9 is tooling 64 oriented at loading
station 66 for handling cartons C-1, C-2 at station 66. Tooling 64
can be stationery or can be vertically or horizontally reciprocated
or tilted as desired.
[0084] Finally, with respect to FIG. 9, it is noted that tooling 60
is in a raised position to receive cartons C-1, C-2 from the Former
Robot 22 (not shown in FIG. 9).
[0085] In FIG. 10, tooling 60 is lowered to initiate transport and
transfer to the loading station 66.
[0086] FIG. 11 illustrates transport of cartons C-1, C-2 to loading
station 66 defined in part by tooling 64. Tooling 62 has been moved
by Loader-to-Closing Robot 36 downstream in the direction indicted
by arrow MF.
[0087] FIG. 12 illustrates the positioning or setting of cartons
C-1, C-2 at loading station 66, on tooling 64.
[0088] FIG. 13 illustrates:
[0089] a) the location of cartons C-1, C-2 on tooling 64;
[0090] b) withdrawal (arrow 74) of tooling 60 by Robot 30,
alternately accompanied by a further lowering of tooling 60;
and
[0091] c) raising of tooling 62 (arrow 76) to raise any cartons
(not shown) which are thereon for final closing.
[0092] FIG. 14 illustrates both the full retraction of tooling 60
by Robot 30; positioning of cartons C-1, C-2 on tooling 64; and
downward retraction or position of tooling 62 by Robot 36.
[0093] FIG. 15 illustrates raising of tooling 60 by Robot 30 to
receive another set or array of formed cartons from Former Robot 22
(not shown); and the partial return of tooling 62 by Robot 36
beneath cartons C-1, C-2 which have been now filled by Overhead
Loader Robot 38 (FIG. 1) while on tooling 64.
[0094] FIG. 16 illustrates the positioning of subsequent cartons
C-3, C-4 on tooling 60 while cartons C-1, C-2 are either set prior
to, during or after top loading at station 66.
[0095] FIG. 17 illustrates the lowering of tooling 60 by Robot 30
and cartons C-3, C-4 to a plane for transport to tooling 64 and the
downstream movement of loaded cartons C-1, C-2 on tooling 62 by
Robot 36, away from tooling 64. In this figure, carton C-2 also has
moved past appropriate guides which fold flap F over into position
for final closing. Glue can be applied to flap F in this area.
[0096] FIG. 18 illustrates transport of cartons C-3, C-4 into
tooling 64 by tooling 60 of Robot 30. Cartons C-1, C-2 are now
partially closed with flaps F over the cartons.
[0097] FIG. 19 illustrates positioning of cartons C-3, C-4 in
tooling 64. Cartons C-1, C-2 are raised on tooling 62 by Robot 36
through closing dies for flap closing and discharge.
[0098] FIG. 20 diagrammatically illustrates the respective
orientation of Robots 30, 36 with robot arms or heads 30a and 36b
respectively, but with end-of-arm tooling removed for clarity;
[0099] FIG. 21 diagrammatically illustrates an alternate embodiment
wherein four transport robots are used, in two sets of two
each.
[0100] In particular, two transport robots 30, 31 facilitate the
former-to-loader transport, similar to that described above, and
two transport robots 36, 37 facilitate the loader-to-closer
transport, also similar to that described above. However, it will
be appreciated that robots 30, 31 each have end-of-arm tooling
moveable in a partially common portion of respective "Z"shaped
paths so that one transport robot 30 can be delivering cartons to
tooling 64, while another transport robot 31 can be receiving
cartons from the gluing and forming area.
[0101] Each robot 30, 31 has a head or arm 30a, 31a and end-of-arm
tooling is mounted thereon. Each robot is capable of Z-axis or
vertical movement so in translation, each is respectively raised or
lowered as desired to prevent interference with the others as they
pass or reset.
[0102] Similar construction and motion is provided by robots 36, 37
with respective arms 36a, 37a.
[0103] In this manner, it will be appreciated that throughput flow
or speeds can be increased with various segments of
former-to-loader or loader-to-closer transport taking place
simultaneously.
[0104] More particularly, FIG. 21 illustrates the position of three
carton arrays situated at various stages noted above in the
foregoing figures, but wherein tooling 64 is fed or unloaded in
this embodiment by additional robots 31, 37. Cartons C-1, C-2 have
been closed, and are ready for discharge from robot 36 while robot
37 is moving to engage cartons C-4, C-3 on tooling 64. Cartons C-3,
C-4 are in the loading position on tooling 64 and cartons C-5, C-6
are located after forming for transport by Former-to-Loader
Transport Robot 31, all as discussed above.
[0105] In FIG. 21, robot arm 31a is positioned to receive cartons
C-5, C-6 from forming while robot 30 as delivered cartons C-3, C-4
to tooling 64. Robots 30, 31, 36, 37 are respectively disposed
end-to-end rather than offset horizontally as in prior figures.
Offset tooling and Z-axis motion cooperate to allow simultaneous
operation of the associated robots continuously or
intermittently.
[0106] Turning now to FIGS. 22-28, an alternative embodiment is
illustrated wherein the invention is particularly adapted to the
cartoning of multiple cups in sleeves such as in the cartoning of
pudding, gelatin or the like. Such cups are packed in tandem rows
in such sleeves with a bottom row extending through holes in the
sleeve bottom and on upper row on top of the lower row and covered
by said sleeve. In this embodiment, like elements bear the same
numbers as previously disclosed in other embodiments.
[0107] It will be appreciated that arrays of four sleeve blanks
90-93 have been fed and formed through the use of the blank feed
and Former Robot 22 of FIG. 1 to end-of-arm tooling 96 on
Former-to-Loader Transport Robot 30. Each blank sleeve 90-93 is
provided with cutouts for receiving product, such as sealed product
cups.
[0108] Another blank array comprising four similar sleeve blanks
100-103 have been handed off to tooling 106 at loading station 108.
Product cups 110 have been loaded onto respective blanks 100-103 as
shown.
[0109] In FIG. 23, relative motion is created between blanks
100-103 and tooling 106 so the blank sleeve is folded up in partial
wraparound of cups 110.
[0110] This operation is further illustrated with further sleeve
folding in FIG. 24.
[0111] FIG. 25 illustrates further transport of sleeves 100-103.
The sleeves 100-103 are picked up by suitable end-of-arm tooling
112 carried by Loader-to-Closer Robot 36. During this motion,
appropriate guides or plows and glue applicators are used to fully
close the sleeves 100-103 around cups 110.
[0112] FIG. 26 illustrates further transport of closed sleeves
100-103 downstream to a discharge station.
[0113] Cartons 100-103 are transported perpendicularly to the
machine flow MF for discharge as illustrated in FIG. 27.
[0114] And in FIG. 26, the sleeves 100-103 have been discharged
downstream in the direction MF. At the same time, subsequent
cartons 90-93 are located in tooling for loading. While not shown
in FIG. 28, tooling 96 may be returned by Robot 30 to receive a
further array of blanks, such as in the position of tooling 96 in
FIG. 22.
[0115] A further alternative embodiment of the invention is
illustrated in FIGS. 29-38. In this embodiment, the structure and
process is the same as previously described with the exception of
the carton feeding, gluing of the blanks and subsequent grouping of
a blank array prior to the downstream forming, filling, closing and
discharge as described above.
[0116] Briefly, in this alternative embodiment, individual carton
blanks 120-122 (FIGS. 29-38) in developed or flat condition are fed
in a first direction from a single magazine 18 at an infeed point
by any suitable blank feeder 17 onto a conveyor 19, preferably
defined as a plurality of belts 123-125, which could be vacuum
belts. A reciprocal suction cup platform 126 (FIG. 31) having a
plurality of suction cups 127 is preferably raised between the
belts 123-125 to receive the blanks and is lowered to deposit them,
sequentially, on the vacuum belts 123-125.
[0117] From there, the blanks 120-122, (FIGS. 34-38) are conveyed
sequentially in the first direction past one or more glue guns 128,
129 (FIG. 33), in this case two glue guns, at a glue station 28a,
where glue is selectively and sequentially applied to the blanks.
After glue is applied, the blanks are conveyed to a blank array
(see FIG. 38) formation area where a predetermined number of now
glued blanks, such as the three blanks 120-122, are oriented in an
array 130 of glued blanks.
[0118] From this position, the entire blank array 130 is picked by
a suitable former robot such as robot 22 and is transferred in a
second direction perpendicular to the first direction noted above
to any suitable former tooling, such as tooling 23, where the
blanks in the array 130 are preferably simultaneously formed into
open-top trays for subsequent loading through their open tops,
closing and discharge as previously described.
[0119] This embodiment of the invention thus provides for the
grouping, in an array 130, of a predetermined number of blanks
(120-122) fed sequentially from a single infeed point, feeder 17 or
magazine 18, and provided with glue prior to further downstream
operations and prior to formulation of an array of glued
blanks.
[0120] Such apparatus can be used in a variety of cartoners where
it is desired to define a plurality of blanks in an array for
subsequent handling of any suitable nature such as described herein
or in any other form of cartoning, whether or not as described
herein.
[0121] It will be appreciated that the carton blanks can be
continually fed to the vacuum belts sequentially, while the blanks
in the formed array can be simultaneously moved into the former
tooling in an intermittent fashion. Moreover, it will be
appreciated that any traditional transport apparatus could be used
to transfer the blanks, after forming, to and through further
downstream cartoning operation.
[0122] In addition, further ancillary equipment (not shown) can be
used to accomplish further tasks in the process, such as leaflet
feeding into the trays, other loading techniques, other closing
techniques, such as using an additional downstream robot 134 to
accomplish tray closing, discharge and the like.
[0123] It will also be appreciated that FIG. 30 illustrates the
overall process of this alternate embodiment. Moreover, while not
shown in FIG. 30, the cartons or trays, after loading and before
final closing, may be passed through a glue station where
appropriate. Where the final cartons are not glued, but comprise
"tuck" type tops, appropriate mechanisms as are well known can be
used to tuck or close the cartons.
[0124] It will be further appreciated that this embodiment provides
for and contemplates feeding blanks sequentially, from a single
magazine and through a single infeed point, gluing blanks
sequentially, thereafter forming an array of two or more glued
blanks at an array station and transferring the array to a
downstream station. Moreover, it will be appreciated that the blank
feeding and blank movement through the gluing application is
accomplished through movement of the blanks in a single direction
or in the same direction, sequentially.
[0125] From this disclosure, it will also be appreciated that all
the robot devices referred to herein, i.e. robots 22, 30, 36, 38,
80 and 82, for example, may comprise any suitable robot apparatus
individually well known. More particularly, and whether or not
technically qualifying as a robot, per se, this apparatus according
to the invention preferably comprises at least a two axis
programmable apparatus sufficient to produce the movements
described herein (such as pick and place) and combined according to
the invention.
[0126] It will be immediately appreciated from the foregoing that
the invention provides several unique advantages. One such major
advantage is the pitchless operation of the invention. In the
embodiment of FIGS. 9-20, for example, carton arrays of two spaced
cartons are handled. In the embodiment of FIGS. 22-28, four
adjacent carton sleeves are handled. This is accomplished by change
out of the end-of-arm tooling on the Robots 30, 36 and perhaps the
tooling at the loading station proximate the intersection of the
Robots 30, 36. Any change out is thus independent of, and does not
require any transport lug changes, chain drive phasing or the like,
and any carton or blank pitch can be accommodated by a simple,
quick end-of-arm tooling change and Robot programming. This
produces a single cartoner capable of handling a variety of carton
sizes and formats, with little concern over carton pitch, or of
machine design, restricted by associated equipment such as loaders,
formers, product feeders, closers and discharge. One basic machine
with relatively small number of change out parts can provide a
manufacturer with a wide range of cartoning capability.
[0127] In this regard, and for example, it is possible with the
invention to adapt a wide variety of loading mechanisms and
functions for use with the invention without having to purchase or
change out the entire cartoner.
[0128] Another aspect of the invention which produces these results
is the unique combination of plural robots or two axis programmable
apparatus in combined overhead and underneath disposition
respecting the cartons. Use of overhead former and loading
apparatus combined with underneath transport apparatus is thus
highly advantageous in producing a multi-functional top load
cartoner.
[0129] Moreover, the ability to use only a single blank feeder to
provide blank arrays in multiple pitch for a variety of varied
pitch carton formats comprises a significant advantage to cartoners
where footprint, cost and adaptability are significant.
[0130] A significant advantage of the invention is the capacity to
provide a cartoning machine and process with both continuous and
intermittent operations in the same cartoning process and
independently so the advantages of these operational formats can be
used to obtain the beneficial aspects of each, as desired, without
restriction by the operation of a separate process segment
operating in a different format. Each operating segment including
carton control, forming, transport, loading, closing and discharge
can each be carried out continuously or intermittently,
independently of and decoupled from other operational segments,
providing beneficial cartoning and overall cartoning
enhancement.
[0131] It will also be appreciated that it is possible to carry out
procedures on the cartons while they are in motion between the
specific stations described herein. In this regard, the arm end
tooling holds and/or manipulates the cartons during their
transport.
[0132] It will also be appreciated that in the embodiments
disclosed, the blanks and formed trays or cartons are maintained
under positive control throughout the process from blank feeding to
loaded and closed tray discharge.
[0133] Finally, it will be appreciated that the carton blanks and
cartons move through a path or a plane as they are fed, glued,
formed, loaded, closed and discharged. The invention contemplates
carton handling by transport robots oriented beneath the path or
plane, and carton loading or other manipulation by robots or other
multiple axis apparatus oriented above the path or plane. Such path
or plane has a "thickness" or depth defined by the carton
travel.
[0134] These and other advantages, embodiments and modifications
will be readily apparent from the foregoing to those of ordinary
skill in the art without departing from the scope of the invention
and applicant intends to be bound only by the claims appended
hereto.
* * * * *