EP0761424A1 - Tray forming and glueing machine - Google Patents

Abstract

The machine has an input station, a transport station with a glue mechanism and an alignment and adhesion station. The machine has three independently controllable motors (M2-M4) with associated motor controllers (E2-E4). A servomotor (M2) drives the input station and a main motor (M3) drives the transport station. A servo motor (M4) which drives the alignment station, forms a linear drive (20) for a tool ram (25). An electronic machine controller (15) has a control program (14) and an associated operating and display element (16) for the entry of parameter values and machining programs.

Description

The invention relates to a tray erecting and gluing machine according to the preamble of independent claim 1. In such machines all stations, i.e. Docking station, transport station as well as erection and gluing station driven by a main motor. This requires long and complex mechanical transmissions with gears, crank drives, cams, etc. from the main engine to the various widely spaced stations. On the one hand, this is very complex and, on the other hand, it also reaches its limits with regard to the desired higher cycle times and production performance. In addition, mechanical wear and the susceptibility to defects increase sharply with the constantly increasing production output required.

Due to the rigid mechanical coupling of the stations, the setting of the machine is severely restricted and also very complex. Conversions to other shell shapes and molding jobs require a lot of work and time. It is also not possible to optimally set the stations individually. In particular, the stamp drive of the erection station cannot be optimally set independently of the main drive of the transport station. This is because the form of movement of the stamp is forcibly determined by the mechanical transmission, for example sinusoidal in the case of a crank mechanism or accordingly a given cam. A change and optimization of the form of movement is hardly possible. Switching to different lifting heights is only possible to a limited extent and involves a great deal of retrofitting. In addition, the machine must be switched off to set the transmissions.

It is therefore an object of the present invention to overcome previous disadvantages and limitations and to create a machine which allows faster cycle times, higher production outputs and more universal use, which produces higher quality and less waste and which, above all, greatly reduces setting and changeover times. Wear, service and repair work should also be reduced as far as possible.

This object is achieved according to the invention with an erecting and gluing machine according to independent claim 1. By means of the construction with three independently controllable motors, each of which drives the application station, the transport station and the erecting and gluing station in the form of a linear drive for the tool stamp and by means of an electronic one Machine control makes it possible to achieve significantly higher production outputs and qualities, to adjust each station with its drive separately optimally to the given molding order and, above all, to be able to carry out conversions to new molding orders very quickly and efficiently.

The dependent claims relate to advantageous developments of the invention which further improve these properties: by a structure with separable modules which can be supplemented by additional modules, by universal adjustability of the stamp in the erection station and by particularly advantageous embodiments of the stamp for multi-lane operation of the machine according to the invention.

All in all, particularly high production outputs with high quality and low susceptibility to rejects and defects are achieved, and the machine can be converted in a very wide range of applications in the simplest way and with minimal effort.

Figur 1

eine erfindungsgemässe Schalen-Aufrichte- und Klebemaschine,

Figur 2

ein Beispiel einer Maschine mit zwei nebeneinander verlaufenden Bearbeitungsbahnen und mit zwei separaten Linearantrieben,

Figur 3

ein Schaltschema der Maschine,

Figur 4, 5

Beispiele von Stempelantrieben der Aufrichtestation,

Figur 6

Beispiele von Hubbewegungen im zeitlichen Verlauf,

Figur 7-10

Beispiele möglicher neuer Bahnanordnungen mit der erfindungsgemässen Maschine.

In the following, the invention is further explained with the aid of examples and figures. Show it:

Figure 1

a tray erecting and gluing machine according to the invention,

Figure 2

an example of a machine with two processing tracks running side by side and with two separate linear drives,

Figure 3

a circuit diagram of the machine,

Figure 4, 5

Examples of stamp drives of the erection station,

Figure 6

Examples of lifting movements over time,

Figure 7-10

Examples of possible new track arrangements with the machine according to the invention.

FIG. 1 shows a tray erecting and gluing machine according to the invention for processing flat blanks 10 with three main modules: a feed station 2, a transport station 3 with a gluing unit 6 and an erecting and gluing station (also a molding station) 4, which modules each have their own drive M2, M3 and M4 with assigned engine control E2, E3, E4. Flat blanks 10 are fed by the feeder 2 individually, for example by means of feeder belt 36 and dosing tongue 37 into a feed roller 38 on a transport chain 18 with drivers 39 of the transport device 3 and passed under a gluing unit 6. Here, the blanks are glued by a glue application roller 41 at predetermined locations. For this purpose, glue spots are attached to the roll 41 and matched to the position of the blanks 10 defined by the drivers 39. Of the Transport station the glued blanks are conveyed further into the erection station 4.

A toothed shaft or pinion shaft 19 serves here as the main drive shaft of the transport chains 18, i.e. a shaft splined across the entire width of the machine (Fig. 2). The transport chain units are driven by a spur gear which meshes with the toothed shaft 19. This enables the transport chains to be shifted and converted particularly quickly, by simply shifting the spur gears along the toothed shaft 19 and / or by replacing spur gears of the transport chains. In contrast, the transport chain units previously had to be removed for retrofitting.

In FIG. 1, a transfer station 5, which is adjustable in the running direction and transverse to the running direction 12, is additionally inserted as a further module between the modules 3 and 4 at the transport station 3. The transfer station 5 conveys the blanks 10 into the forming station 4 by means of conveyor belts 32. The module 5 is also driven by the motor M3 of the transport station 3 via a transmission 17.

An adjustable stop 43 defines the correct position of the blanks 10 for the subsequent erection and gluing step. A tool stamp 25 with a molding tool 30 pushes the blanks upwards into a molding shaft 44 in the direction 29, whereby they are folded in a coordinated interaction of the tool shape, molding shaft and stamp movement, brought into the desired final shape and glued at the predetermined locations. In rapid succession, further shaped shells 11 are continuously pushed in and put inside one another as conical shells and are kept in shape so far or long that the glue can set and the shell no longer separates.

The modular construction of the new machine also makes it easy to insert additional modules. As an additional module 7 in front of the glue station 6, for example, printing or labeling stations can be installed and integrated. The gluing unit 6 can also be quickly replaced or supplemented. For example, a hot melt gluing unit can also be installed, or instead of a cold gluing unit with application rollers, one with nozzles and valves can also be used, which are also controlled by the machine control 15. It is also possible to place additional production units such as page folding or pre-folding devices between the separable modules.
The modular machine structure with separate module drives also enables the transitions 2/3, 3/5, 5/4 between stations 2, 3, 5, 4 to be optimally adjusted or adjusted - even during operation. For example, during the transition 2/3 from the feeder 2 to the transport station 3, the parameter "cut length" can be optimally adjusted to the desired operating conditions and to the cuts 10 and also adjusted. The same applies analogously to the transitions 3/4 or 5/4 into the forming station 4, with which the blanks 10 are brought into an optimal starting position before the stamping process.
Suitable sensors D and adjusting elements (eg stop 43) are arranged and connected to the electronic control 15 for setting and monitoring the machine, operation and production process.

FIG. 3 shows a circuit diagram of such a machine according to FIG. 1 with the separate drives M2, M3, M4 of the modules 2, 3, 4 and the associated motor controls E2, E3, E4, which are connected to an electronic machine control 15. The machine controller 15 contains operating programs 14 and parameter values and is connected to detectors and sensors D, which are used for monitoring and setting the machine. An operating and display device 16, for example a display with a keyboard, enables the input of operating programs and setting parameters as well as the acquisition and evaluation of machine and production data. Via a bidirectional output 35, an external operating and display device 16, for example for several machines together, can additionally or alternatively be connected.

Figure 2 shows schematically from above another example of a machine with two machining tracks 13.1 and 13.2 running side by side. The modules 2, 3 and 5 are driven by a separate motor M2 or M3 in modules 2, 3 and 5, the motor M2 driving both feeders of the two trains synchronously and the motor M3 both transport chains 18.1, 18.2, both gluing units 6.1, 6.2 and drives both conveyor belt units 32.1, 32.2. This example shows a variant with two separate drives M4.1 and M4.2 for the two forming tools 30.1 and 30.2 of the forming station 4, whereby - within the scope of the same conveying speed and cycle times of the tracks 13.1 and 13.2 - different lifting movements can be carried out, which correspond to different Blanks 10.1 and 10.2 and molding processes can be coordinated. Then the separate punch movement directions 29.1 and 29.2 could take place at an angle W2 or W2.1 and W2.2 transversely to the machine direction 12 instead of vertically and e.g. lead into two side discharge modules 8.1, 8.2. However, the simplest variant, as also shown in FIG. 2, consists in only one stamp motor M4, which moves both molding tools 30.1 and 30.2 synchronously, e.g. by means of a T-shaped stamp as shown in Figure 4.

FIGS. 4 and 5 show examples of erection and gluing stations 4 which have more than one mold 30 (for example two to four molds) for as many parallel processing tracks 13. This naturally results in particularly high production outputs and also a large one Area of application of the machine according to the invention. This is because the same machine can process both single-lane cut-outs and, after simple retrofitting, smaller-sized blanks in parallel.

Figure 4 shows an example with a motor M4. The linear drive 20 consists of the motor M4 and a linear conveyor unit 21 driven thereby. This has a rotating toothed belt 22, which moves a T-shaped punch 26 in the direction 29 via a suitable fastening. Two molds 30.1 and 30.2 are attached to the stamp. The possible stroke movement is Hmax and a set working stroke H between the start position Ha and the end position He is shown as an example. Thanks to the separate, freely controllable drive M4 or 20 according to the invention, the stroke H as well as the start and end positions Ha and He can be optimized, set and adjusted as desired while the machine is running. Timing belts are particularly suitable for such linear conveyors. The linear drive can also be designed as a linear motor.

Figure 5 shows an example with a motor M4, which drives two linear conveyor elements 21.1 and 21.2 arranged on both sides of the machine synchronously via a common shaft 46, e.g. acting on the racks of the linear conveyor elements via pinions on the shaft 46. The linear conveyor elements 21.1 and 21.2 together with the carrier 28 form a yoke-shaped tool stamp 27 which carries four tools 30.1 to 30.4 here.

The advantages of the separate drive control according to the invention of the linear drive 20 or of the motor M4 of the erection and gluing station 4 are further explained on the basis of FIG. 6 compared to previous machines.

6a shows the acceleration curve a (t) of the lifting movement or the plunger movement as a function of time t. In previous machines driven by only one main motor, the punch drive was mechanical, e.g. connected to the constantly running main engine via a crank mechanism. This results in a sinusoidal stroke movement and thus also a sinusoidal acceleration curve according to curve a1 (t). With the new machine, however, the punch drive 20 can be controlled as desired, independently of the other separate motors M2 and M3, and thus a form of movement that is optimally adapted to the machine and the respective processing process can be specified. For example, the stroke movement can be carried out with a permissible constant acceleration a according to the rectangular curve a2 (t). Then, with the same stroke time tH and the same maximum acceleration, a correspondingly larger stroke is completed than in the case of the previous sine curve a1 (t). Or vice versa: to achieve the same stroke H, the new machine with constant acceleration only needs a much shorter stroke time than after a1.

The permissible maximum acceleration is limited by the masses to be moved. Since these, in turn, are smaller in the new separate drive M4 according to the invention than previously, even higher acceleration can be achieved, as is shown by curve a3 (t). This significantly reduces the stroke time tH3. Or conversely, with the same cycle time and lower acceleration, the mechanical load, wear, maintenance and repair work can be greatly reduced in accordance with the lower acceleration forces. The acceleration can also be controlled by the torque of the linear drive in such a way that the total forces that occur (ie the mass acceleration forces and the deformation forces as a result of shaping and pressing for gluing) assume a desired optimal value.

Appropriate sensors (for position, pressure, speed, etc.) can also be used to monitor and optimize the stroke movement.

FIG. 6b shows speed profiles V (t) as a function of time. The curve V1 (t) in turn represents a previous sinusoidal speed curve with a stroke time tH1. An exemplary course V2 (t) of the new machine first shows a rapid start-up, then a reduction in speed to a value VD, with which a certain zone of the mold shaft is traversed more slowly for a certain time tD (if this is favorable for the shaping) . Subsequently, V2 (t) drops to zero, so that the stamp remains in the upper stroke end position He for a time tS (for example for the purpose of pressing the glue firmly). This is followed by a rapid downward movement of the plunger with constant acceleration or deceleration a (with v = at) to the lower stroke starting position Ha. This in turn results in the shortest possible stroke times tH2, or time to stay in areas or positions where shaping and gluing processes can be improved. In the example according to FIG. 6b, the new speed curve V2 (t) enables both a shorter stroke time tH2 and residence times (tD, tS) compared to the previous curve V1 (t). In particular, the downward stroke can be done much faster than before.
In short, this means that the stroke movement can be optimally adjusted, designed and readjusted in accordance with the requirements of a machining process with regard to the course of acceleration (forces), speed (molding process) and any intermediate stops (pressing, bonding).

FIGS. 7 to 10 schematically illustrate the large number of possible new path arrangements, which are only possible thanks to the separately motorized ones Modules of the machine according to the invention are possible. The webs 13 with the direction of travel 12 of FIGS. 7 to 9 have a horizontal course in the transport station 3. The movements 29 of the plunger of the erection station 4 are inclined at an angle W1 to the vertical, which is easily and universally adjustable thanks to the separate linear drive 20.

In the example of FIG. 7, the web 13 is bent upwards in the transfer unit 5, whereupon the stamp direction takes place with the angle W1 upwards and backwards. A removal module 8 in the opposite direction to 12 can connect here. Then the blanks are fed in and the finished molded shells are removed close to one another. This also results in a particularly short and compact machine.

In the example of FIG. 8, the web 13 is bent downward at a right angle by the angle W1 to a forming station 4 with a horizontal stamp movement direction. Here, e.g. Connect a discharge device, which conveys finished trays in layers from below upwards (47) for removal from above.

In the example of FIG. 9 with the transport station 3 being fed horizontally, the stamp direction is at an angle W1 of 180 ° downwards. A removal device 8 could deposit the trays in a stack next to one another on a pallet 48 that can be moved in a controlled manner, the displacement of the pallet for depositing the tray stacks being connected to the machine control 15.

FIG. 10 shows an example with a non-horizontal path 13. The transport device 3 is here inclined downward by an angle W3 of, for example, 10 to 15 °. The direction of the stamp is perpendicular to it at an angle W1 = W3. This results in a lower end of the shaped shaft. Removal can then take place at a comparable level with investor 2. The examples illustrate the many possible designs of the web guides, which can be optimally adapted to certain machining processes and other boundary conditions.

The following are some more options and advantages of the new modular machine:

Stamps and feeders can be individually coordinated using open parameters. This is particularly advantageous for deep shells.
By changing the machine parameters, the start of the individual module drives can be delayed, accelerated or suspended as required.
Because the drives are not mechanically linked to each other, each drive can run any interval independently of the others. Every 50th stroke can be extended, for example, to better unstack the finished shells.
The stamp and its drive can be installed in any position. There are no major design changes because there is no mechanical coupling with other machine parts and drives.
Since the feeder and the stamp motor are independent drives, they can also be switched off for certain operating modes, depending on the requirements. This brings advantages for cleaning or work breaks, for example. The gluing unit, which is driven by the main motor M3 of the transport station, can then continue to run at reduced speed alone during cleaning work or work breaks, without the feeder and stamp having to run with it. This operating mode is necessary during work breaks so that the glue does not dry out.

The stamp can remain in any position, especially in the upper and lower end positions. This can e.g. can be used for inserting additives in the shells or for longer setting times. A standstill and keeping under pressure in the upper end position He can also be used to "weld" the shell material, e.g. using a heated stamp or using ultrasonic welding.

• Einstellbetrieb mit separatem Lauf jeder Station solange eine entsprechende Taste gedrückt ist.
• Automatischer Betrieb mit vorgegebenen Einstellungen
• Einstellung und Änderung von Produktionsparametern wie Maschienengeschwindigkeit, Zuschnittlänge, Einlaufhöhe, Hubpositionen, Hub, Markierungen
• Zeitlicher Ablauf der einzelnen Antriebe relativ zueinander
• Datenerfassung, z.B. Stückzahlen, Ausfälle etc.

The machine control or control programs can be used to:

• Setting mode with separate run of each station as long as a corresponding key is pressed.
• Automatic operation with predefined settings
• Setting and changing production parameters such as machine speed, cutting length, inlet height, stroke positions, stroke, markings
• The timing of the individual drives relative to each other
• Data acquisition, e.g. quantities, failures etc.

Label list

2nd

Docking station

3rd

Transport station

4th

Erection and gluing station (forming station)

5

Transfer unit

6

Gluing unit

7

additional modules, stations

8th

Discharge module

10th

Blanks

11

shaped bowls

12th

Machine running direction

13

Processing lanes

14

Control program

15

electronic machine control

16

Operating and display instrument

17th

transmission

18th

Transport chain

19th

Toothed shaft, main drive shaft

20th

linear actuator

21

Linear feed unit

22

Timing belt

25th

Tool stamp

26

T-shaped stamp

27

yoke-shaped stamp

28

Tool carrier

29

Direction of stamp movement

30th

Molding tool

32

Conveyor belts from 5

35

bidirectional output

36

Feeder belt

37

Dosing tongue

38

Pick roller

39

Carrier

41

Glue application roll

43

attack

44

Molded shaft

46

common wave

47

Layer stacking

48

coordinated palette

2/3

Transfer from 2 to 3

3/5

5/4

etc.

M2

Engine of 2

M3

Engine of 3

M4

Engine of 4

E2, E3, E4

Engine controls

H

Working stroke

Hmax

maximum stroke

Ha

Stroke beginning

Hey

Stroke end position

V

speed

a

acceleration

V1, a1

so far

V2, a2, a3

New

W1

Angle to the vertical in the running direction

W2

Angle perpendicular to the running direction

D

Detectors, sensors

tS

Stop time, stop

tD

slow speed range

tH

Stroke cycle times

Claims (15)

Tray erecting and gluing machine for processing flat blanks with a lay-on station, a transport station with a glue unit and a stand-up and glue station, characterized by three independently controllable motors (M2, M3, M4), each with an assigned motor control (E2, E3, E4), with a servo motor (M2) as the drive of the docking station (2), a main motor (M3) as the drive of the transport station (3), and a servo motor (M4) of the erection station (4), which as a linear drive (20) for one Tool stamp (25) is formed and by an electronic machine control (15) with a control program (14) and by an associated operating and display element (16) for entering parameter values and operating programs. Machine according to claim 1, characterized in that the application station, the transport station and the erection station are designed as separable modules (2, 3, 4). Machine according to claim 2, characterized in that it contains a transfer unit (5) and / or additional modules (7). Machine according to claim 2, characterized in that a discharge module (8) connected to the machine controller (15) is connected. Machine according to claim 1, characterized in that the drives (M2, M3, M4) are designed as interchangeable modules. Machine according to claim 1, characterized in that the direction of movement (29) of the plunger (25) of the erection station can be adjusted with its linear drive (20) at an angle W1 in the running direction (12). Machine according to claim 1, characterized in that the direction of movement (29) of the plunger (25) of the erection station with its linear drive (20) is adjustable at an angle W2 transverse to the direction of travel (12). Machine according to claim 1, characterized in that the direction of movement of the plunger (25) can be adjusted vertically downwards. Machine according to claim 1, characterized in that the drive of the transport station (2) has a continuous toothed shaft (19) as the main drive shaft for transport chains (18). Machine according to claim 1, characterized in that the linear drive (20) of the plunger has a linear conveyor unit (21) driven by the servo motor (M4) with a toothed belt (22). Machine according to claim 1, characterized in that the erection station (4) has more than one linear drive (20) for a plurality of processing tracks (13) running side by side. Machine according to claim 1, characterized in that the linear drive (20) of the erection station has a T-shaped punch (26) which carries at least two tools (30). Machine according to claim 1, characterized in that the linear drive (20) has a yoke-shaped punch (27) which carries at least two tools (30). Machine according to claim 1, characterized in that the linear drive (20) has a servo motor which drives two lateral linear conveyor units (21.1, 21.2) connected by a tool carrier (28) synchronously. Machine according to claim 1, characterized in that sensors and detectors D connected to the machine controller (15) are provided for function monitoring and for determining parameter values.

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