IT202100014867A1 - PACKAGING PROCESS AND PLANT FOR PACKAGING ONE OR MORE OBJECTS IN BOXES. - Google Patents

Description

"PROCESS AND PACKAGING PLANT FOR PACKAGING ONE OR MORE OBJECTS IN BOXES"

FIELD OF APPLICATION

The present invention refers to a method and to a packaging plant for automatically or semi-automatically packaging objects of various types and sizes inside boxes, the dimensions of which are defined according to the size of each batch, or set of objects to be introduced into them. This invention can find application, for example, but without limitations to the generality, for the packaging and sorting of items purchased by mail, even in electronic form, for example in the context of electronic commerce.

STATE OF THE ART

In the context of systems for shipping objects, deriving, for example, from purchase orders made online, ? note the need to introduce, in a plurality? of empty boxes, the objects associated with a specific purchase order made by a customer, to then proceed with the shipment of the package to the address indicated by the latter.

Normally, because each purchase order can relate to various objects, having shapes, weight and dimensions the pi? different from each other, even the relative box must be chosen appropriately, so that it is the most? small as possible, but still able to contain all the objects associated with a given order.

For this reason, usually, a plurality of of types of boxes of standardized dimensions, based on their dimensions and therefore on their capacity.

Typically, a plant canning station is? fed both with empty boxes of different types, and with different lots of objects of different nature and size, to be introduced each in an appropriate box, in which each lot brings together a single object or a plurality? of objects belonging to the same purchase order.

Nowadays, especially large electronic commerce (ecommerce) companies find themselves in the need of? to manage and process several thousand purchase orders per day. Consequently, each object introduction station must have a high productivity? and flexibility? and each operation of introducing objects into boxes, including choosing the right box, must be done in a very short time. Furthermore, ? It is necessary to maintain an optimization of the volume occupied by the objects inside the box, both to reduce the consumption of packing material and to make it more? efficient transportation. In some solutions, the format of the box more? appropriate ? chosen by the operator or suggested to the operator by a visual system, for example through video instructions. Normally, in an object introduction station, a suitably trained operator first chooses a carton of the appropriate format, among a plurality of of cartons of different standardized sizes. Such cartons generally have four consecutive sidewalls, connected by fold lines, four bottom flaps and four top flaps. Furthermore, these cartons are typically supplied in a flattened shape with the upper flaps downwards so that the operator can remove the carton, proceed with forming the relative box, close the bottom, rotate it, insert a batch manually of objects associated with a certain purchase order, and close it at the top, so? that each batch of objects is contained in the box more? appropriate. In this way, by picking up the cardboard with the upper flaps facing downwards, the operator only has to rotate the box once. After that? the packaging of the box with the lot of objects inside? sent to a storage and/or shipping station. Simultaneously, another operator, suitably instructed, prepares the individual batches of objects each corresponding to a certain purchase order and places them at the disposal of the operator in charge of the station for introducing objects into the boxes.

A drawback of the aforementioned manual introduction of objects? which is slow and expensive.

An additional drawback? that the above operations are highly repetitive for an operator to carry out.

Furthermore, another drawback of the prior art? that the sequence of operating phases for the packaging of each box with a batch of objects inside, which goes from the choice of the relative carton to the closure of the box itself, does not allow the operator in charge of the station for introducing objects into the boxes to deal with a subsequent batch of objects, i.e. from another purchase order, until he completes the entire sequence. Since the time interval to carry out the operative phases for the packaging ? greater than the time required to prepare a batch of objects relating to another purchase order, c?? a temporary interruption of this?last operation, which can? resume only when the operator in charge of the object introduction station has completed the operating phases relating to a box and therefore to a certain purchase order.

Fully automated machines are also known, which however are such as to process only stackable objects. Furthermore, these known machines have large dimensions, are very complicated and are therefore not very suitable for logistics plant environments where there is no specialized technical staff and, lastly, they are not very flexible. In particular, some of these known solutions are known in the field with the term "wrap-around". They envisage making the box directly around the objects to be boxed starting from a single sheet of cardboard in an extended condition. These solutions, although appreciated why? they allow to minimize the volume of the package to be shipped, they are suitable only for the packaging of stackable products. Furthermore, these latter known solutions necessarily require complicated, bulky and expensive equipment, and the presence of a specialized operator to carry out the correct arrangement of the stackable objects entering the machine. Another drawback of these last known solutions? that the speed? with which the objects are wrapped must be rather small to avoid that the latter are positioned incorrectly, falling from the pile in which they are arranged.

A further drawback of ?wrap-around? ? that do not provide the possibility? to insert filling material or ?filler? into the box.

Is there therefore a need? to perfect a method and a packaging plant for automatically or semi-automatically packaging objects of various nature and size inside boxes, which can overcome at least one of the drawbacks of the technique. To do what? ? It is necessary to solve the technical problem of automating at least the box forming phase and to associate, automatically and in the correct timing, the phase of forming each box with the preparation of each batch of objects associated with a certain purchase order.

Therefore, an object of the present invention is that of developing a procedure and supplying a packaging plant for packaging objects of various nature and size inside boxes, in which, at least, the creation of the boxes takes place in the most possible automated, i.e. without the substantial intervention, or with minimal intervention, of personnel.

Another object of the present invention ? that the automatic creation of the box takes place sufficiently in advance of when the operator takes the batch of objects to be placed in the box associated with a specific order.

Yet another object of the present invention? that of developing a process and supplying a packaging plant for packaging objects of various nature and size inside boxes, in which the box forming phase is correlated to the preparation phase of each batch of objects associated with a certain purchase order.

Another object of the present invention ? that of developing a process and supplying a packaging plant for packaging objects of various nature and size inside boxes, in which the forming of each box is automated and timed with the preparation of a specific batch of objects associated with a specific order and such that the dimensions of the box are the pi? small possible, at least compatibly with the overall volume of the lot of objects that must contain, associated with a certain purchase order, to reduce cos? costs and volumes and not waste material.

Another object of the present invention ? that of developing a procedure and supplying a packaging plant to package objects of various nature and size inside boxes, which are simple, safe and reliable.

To obviate the drawbacks of the prior art and to obtain these and further objects and advantages, the Applicant has studied, tested and implemented the present invention.

DISCOVERY DISPLAY

The present found ? expressed and characterized in the independent claims. The dependent claims disclose other characteristics of the present invention or variants of the idea of the main solution.

In accordance with the aforesaid purposes and to solve the aforesaid technical problem in a new and original way, also obtaining considerable advantages with respect to the state of the prior art, a packaging method according to the present invention for packaging one or more? items in boxes includes:

- provide one or more objects grouped into respective lots, each lot being associated with a respective purchase order;

- prepare at least one? unit? storage comprising a plurality? of flattened cartons of different sizes;

- choose, among the lots supplied, a lot to be packaged in accordance with a given production time schedule;

- withdraw from that at least one? unit? of storage a carton from that plurality? cartons in flattened condition, by means of picking means; - opening the taken carton to form an open box at the top having side and front walls and a bottom wall, by means of forming means;

- closing the back wall, by means of closing means;

- delivering the box open at the top to an object introduction station;

- introducing, in said introduction station, the chosen batch of objects into the box open at the top;

- close the upper opening of the aforementioned box e

- transfer the closed box to further processing stations, or to shipping.

In accordance with an aspect of the present invention , the aforesaid removal of the aforesaid cardboard in a flattened condition ? carried out on the basis of an automatic selection of a specific cardboard in a flattened condition among the plurality of cartons in a flattened condition of different sizes, which correlates a capacity? of containment of the corresponding box in open three-dimensional condition, obtained with the opening of the aforementioned carton, with a volumetric bulk of the chosen lot of objects to be introduced into the aforementioned box in order to withdraw from the aforementioned at least one? of storage the cardboard whose open box offers a volume that more? approaches the volume from the batch to be introduced.

Advantageously, by means of the process described here? Is it possible to take the cardboard of the right size, in relation to the batch of objects to be introduced, from a? unit? container containing flattened cartons of different sizes. The operator, therefore, will receive? automatically a box of the minimum dimensions for the volume of the batch of objects to be introduced; this box will be already closed at the bottom and open at the top. The operator will have therefore only the task of introducing the objects into the box while the forming of the box intended for the introduction of the batch of objects of the next order and the final upper closure of the box in which they are? the batch of objects of the previous order has been introduced, they occur in temporal overlap.

In accordance with another aspect of the present invention, the method provides for synchronizing an expected completion time of preparation of a specific batch of one or more? objects and correlate the? volumetric footprint of one or more? objects of the aforementioned specific lot with the operations envisaged for the removal of the cardboard from the warehouse, the opening of the cardboard taken to form the box open at the top and the closing of the back wall.

In accordance with another aspect of the present invention , the method envisages that the phase of introducing, into a box already formed and closed on the bottom, of one or more? objects of a specific lot is carried out in at least partial temporal overlap with one or more? of the operations envisaged for the withdrawal of the subsequent carton from?at least one?unit? of storage, the opening of the box taken to form the next box open at the top and the closure of the relative back wall.

In accordance with another aspect of the present invention , the method provides that the supply of the aforesaid box formed and closed at the bottom comprises automatically transferring the aforesaid formed carton in an open three-dimensional condition defining the aforesaid box towards the aforesaid introduction station in which to introduce, in the the aforementioned box, the one or more? objects of the aforementioned specific lot.

In accordance with another aspect of the present invention , the method provides for supplying a signal containing information correlated with the volumetric size of the determined batch of one or more? objects to be introduced in the aforementioned box and possibly also the dimensions of a coordinated box and to associate, for the purposes of the aforementioned automatic withdrawal, the aforementioned information contained in said signal to a specific carton of a plurality of cartons in flattened condition, grouped into predefined groups based on respective dimensions related to capacity? containing the aforesaid boxes in an open three-dimensional condition obtainable from each of the aforesaid cartons.

In accordance with another aspect of the present invention , the method provides that the aforesaid one or more? objects grouped in respective lots each associated with a purchase order are supplied to a supply station which provides for a temporary warehouse provided with compartments each configured to house a respective lot of the aforementioned one or more? objects.

In accordance with another aspect of the present invention , the aforementioned temporary store comprises a plurality of of pass-through compartments in each of which can? be brought in a batch of the above items.

In accordance with another aspect of the present invention , the aforementioned compartments are arranged at different heights, for example according to a matrix of rows and columns, with the rows at different heights.

In accordance with another aspect of the present invention, the aforesaid compartments have a loading opening, for loading the aforesaid objects, and an opposite withdrawal opening, advantageously arranged on the side of the aforesaid introduction station.

In accordance with a further aspect, alternatively the procedure provides that the aforementioned one or more objects grouped into respective lots each associated with a purchase order are supplied directly to the object introduction station by means of an automatic conveyor device, each of the lots being temporarily positioned inside a container, such as a tray, box or small tub. The automatic conveyor device? synchronized in time with a work program associated at least with the automatic picking up of the boxes and their subsequent forming, so as to give the necessary time for picking up and forming the box itself, and possibly also for the operation? of the object introduction station.

In accordance with another aspect of the present invention , the method provides that the step of providing one or more? objects grouped into respective lots each associated with a purchase order either manually or automatically.

In accordance with another aspect of the present invention , the method provides that the automatic selection of the aforementioned carton is carried out optionally on the basis of one or the other of the following operations:

- direct a priori correlation between volumetric bulk information of a specific batch of objects to be introduced in a certain box and capacity information? containment of the aforementioned box in an open three-dimensional condition obtainable from a given flattened cardboard. In particular, the information of the dimension of the box can? come from a warehouse management system which, knowing which objects make up the lot associated with the order, on the basis of specific algorithms, provides the dimensions, and therefore the capacity? of containment, of the corresponding box;

- insertion of a request for a specific box to be selected on the basis of a specific batch of objects to be placed in the aforementioned box;

- optoelectronic acquisition in real time of information relating to the volumetric size of a specific batch of objects to be introduced in the aforementioned box and correlation of the aforementioned information with the capacity? containment of the aforementioned box in an open three-dimensional condition obtainable from a given flattened cardboard. In accordance with another aspect of the present invention, the method also provides a step of providing, manually or automatically, the aforementioned plurality of of cartons in flattened condition, grouped into predefined groups based on respective dimensions related to capacity? containing the aforesaid boxes in an open three-dimensional condition obtainable from each of the aforesaid cartons.

In accordance with another aspect of the present invention, the method provides that the aforementioned plurality of cartons in the flattened condition and grouped into groups are supplied to an automatic forming equipment comprising at least one unit? equipped with seats each configured to house, arranged on a corresponding support surface, a respective group of cartons, in which each carton is preferably positioned inclined on the respective support surface.

In accordance with another aspect of the present invention, the method provides that the aforementioned plurality of cartons is arranged on the aforesaid support surfaces of each seat in a repeatable and automatically recognizable reference position, determined by a corresponding abutment element or limit switch.

In accordance with another aspect of the present invention, the method provides that each of the aforementioned cartons is formed by four consecutive walls connected to each other by folding lines, by four lower flaps, arranged on one side of the aforementioned four walls, foldable and having dimensions matched to the plan dimensions of the relative box and preferably not modifiable, and by four upper flaps, arranged on the opposite side with respect to the aforementioned four lower flaps. These four upper flaps can be folded to adapt to measure the plan dimensions of the relative box and in particular also to the height of the box (so-called ?down-sizing? operation), and therefore to the aforesaid capacity? of containment, a function in turn of the volumetric footprint of the specific batch of one or more? items to put in the box.

In accordance with another aspect of the present invention , the method provides that the step of introducing, into each box, respective one or more objects of a certain lot also includes the insertion, possibly automatic or manual, of filling material in the aforementioned box to at least partially fill the empty spaces left by the aforementioned one or more? objects.

In accordance with another aspect of the present invention , the method provides that the closure to measure of the aforementioned box in which at least the aforementioned one or more have been introduced? objects is carried out by manually adapting the box in height (?down-sizing?), cutting any parts of the aforementioned box and closing the upper flaps of the box so? obtained, or automatically, by optoelectronic acquisition of the aforementioned box and of the objects contained therein, for example dimensions of the box and objects, in particular at least height, and subsequent resizing of the aforementioned box by means of cutting means configured to automatically cut parts of the aforementioned box into based on the aforementioned optoelectronic acquisition to obtain upper flaps of the box which can be closed automatically.

In accordance with another aspect of the present invention, the method provides that the aforementioned boxes, into which the objects have been introduced, are closed to size in a closing station, favorably carrying out the height adjustment operations (?down-sizing? ) and top closure. The boxes, before being closed to size, or after these operations, for example in the case in which the closing to size is carried out manually, can be transferred automatically by means of vertical movement means from a first level associated with a work plane of the aforementioned object introduction station, or of the closing station, if provided, at a second lowered level, associated with means of transport configured to transport the aforementioned packed and closed boxes towards a warehouse, or a shipping station. In accordance with another aspect of the present invention , the method provides that if the closure to size of the aforementioned box is carried out automatically, the automatic operations of the aforementioned closing to measure can be carried out when the boxes are already? been placed on the lowered second level. Alternatively, one or more operations of the aforesaid closing to size could be carried out automatically while the aforesaid boxes are lowered from said first level towards said second level.

In accordance with another aspect of the present invention , the method provides that each carton in a flattened condition is supplied in a determined picking position so as to expose a folding line outwards between two consecutive walls of the aforementioned carton suitable to respectively define a side wall, or side, of said box and a front wall of said box; moreover, the automatic withdrawal of a respective carton ? carried out by applying a gripping force on both surfaces astride the aforesaid folding line, so as to keep the aforesaid cardboard in a flattened condition during the automatic withdrawal phase.

In accordance with another aspect of the present invention , the method foresees that the automatic withdrawal of a respective flattened condition carton is carried out by applying the aforementioned gripping force on two consecutive side and front walls of the aforementioned box in an internal region of the same carton between the respective fold lines which delimit the opposite upper walls and bottom walls of said box. In accordance with a further aspect of the present invention, a packaging plant, for packaging one or more? items in boxes, includes:

- a feeding station of one or more? objects grouped into respective lots, each lot being associated with a respective purchase order in accordance with a given production time schedule;

- an introduction station to introduce, in a box, one or more? objects of a certain batch;

- a closing station for closing to size and transferring the aforementioned box, into which objects have been introduced, towards further processing, or towards shipment. Furthermore, the packaging plant comprises a forming apparatus configured to carry out both an automatic removal of a corresponding carton supplied in a flattened condition, and a subsequent automatic forming of the aforementioned carton in an open three-dimensional condition defining the aforementioned box with upper opening, and the closure of the back wall of the aforementioned box. Furthermore, the aforesaid forming equipment ? configured to carry out the aforementioned automatic withdrawal of the aforementioned corresponding carton in a flattened condition on the basis of an automatic selection of the aforementioned carton from a plurality cartons in flattened condition of different dimensions present in a?unit? storage, in which a? unit? control ? configured to correlate a capacity? of containment of the corresponding box in an open three-dimensional condition, obtained with the opening of the aforementioned carton, with a volumetric size of the chosen lot of objects to be introduced into the aforementioned box in order to withdraw from said at least one? of storage i the cardboard whose open box offers a volume that more? approaches the volume from the batch to be introduced.

In accordance with a further aspect of the present invention, the aforementioned unit? control ? configured to synchronize an expected completion time of preparation of a specific batch of one or more? objects and correlate the? volumetric footprint of one or more? objects of the aforementioned specific lot with the operations envisaged for the withdrawal of the cardboard from the aforementioned at least one?unit? of storage, the opening of the carton taken to form the open box at the top and the closure of the back wall.

Advantageously, the information on the volumetric size of a specific batch of objects to be introduced into a box at a specific instant in time, which, as indicated above, for example can be known in advance or acquired in real time, can determine the selection and automatic withdrawal of a cardboard to be formed, having determined and correlated volumetric dimensions, in particular length, width, and height. According to advantageous embodiments of the present invention, a command to form the specific and determined box is provided before the correlated batch of objects arrives at the object introduction station, so that the formed box then arrives at the nearest station. short possible time in the area for introducing the objects, in synchrony with the aforementioned specific instant of time for the purpose of introducing the objects and closing the top of the box itself.

In accordance with a further aspect of the present invention, the aforementioned unit? control ? configured to synchronize? introduction, in a box already? formed and closed on the bottom, of one or more? objects of a certain lot so that the aforementioned introduction is in at least partial temporal overlap with one or more? of the operations envisaged for the removal of the next carton, the opening of the carton picked up to form the next box open at the top and the closure of the relative bottom wall.

In accordance with a further aspect of the present invention, the aforementioned unit? control ? configured to provide a signal containing information correlated with the volumetric size of the given lot of one or more? objects to be introduced into the aforementioned box and possibly also the dimensions of a coordinated box, and to associate, for the purposes of the aforementioned automatic withdrawal, the aforementioned information contained in said signal to a specific carton of a plurality of cartons in flattened condition, grouped into predefined groups based on respective dimensions related to capacity? containing the aforesaid boxes in an open three-dimensional condition obtainable from each of the aforesaid cartons.

In accordance with a further aspect of the present invention, the aforesaid forming apparatus comprises:

- said at least one unit? of storage, which ? provided with seats which communicate with each other in a common upper transfer space and each suitable for housing, arranged on a corresponding support surface, a respective group of cartons;

- a first sampling organ positioned inside the aforementioned unit? of storage to fit into the aforementioned locations and equipped with one or more? gripping elements configured to selectively grip in a stable manner a respective cardboard in a flattened condition, which first picking member ? associated with two carriages slidingly positioned on two respective linear guides installed on the aforementioned unit? of storage, of which a first horizontal and a second vertical, so that the aforesaid first drawing member is movable in at least two degrees of freedom? linear, respectively in height and length along the aforementioned guides associated with the aforementioned unit? of storage, in which, moreover, the aforesaid first drawing member ? associated with a drive member configured to rotate said first pickup member about its own development axis;

- a second picking member configured to cooperate with said first picking member to receive said cardboard in flattened condition, which second picking member ? equipped with one or more gripping elements and ? mounted on a respective carriage slidably positioned on a linear guide arranged vertically in the aforementioned unit? of storage;

- forming means associated with the aforesaid second drawing member and provided with one or more? rotating lever elements equipped with one or more? gripping portions suitable for selectively coupling with one or more? portions of said carton for rotating the latter and causing an open three-dimensional condition of said carton defining said box; And

- bottom closing means configured to close the bottom of said box.

According to embodiments, the aforementioned linear guide ? mounted on a translation device operated by a relative motor to selectively determine a horizontal translation motion of the linear guide with respect to the aforementioned bottom closing means.

In accordance with a further aspect of the present invention, the aforementioned unit? control ? configured to selectively control, directly or indirectly, both the linear movement of the aforesaid two trolleys along the aforesaid linear guides and to actuate the aforesaid driving member to rotate the aforesaid first picking member around said development axis, so as to overall determine a combined motion of the aforementioned first pick-up member along a resulting at least partly curvilinear trajectory, so that? a flattened cardboard taken from a respective group of inclined cardboards can rotate to release itself from the aforementioned group of cardboards and be positioned substantially horizontally in said upper transfer space common to said seats, can then be transferred linearly towards the aforementioned second picking member and be rotated again to be delivered to the aforesaid second picking member.

In accordance with a further aspect of the present invention, the aforementioned one or more? gripping elements of the aforesaid first pick-up member are configured to apply a gripping force on both sides straddling a folding line between two consecutive walls of the aforesaid carton adapted to respectively define a lateral wall, or side, of the aforesaid box and a front wall of said box, so as to keep said cardboard in a flattened condition during the automatic removal step.

In accordance with a further aspect of the present invention, the aforementioned one or more? gripping elements of the aforesaid first pickup member are configured to apply a gripping force on two consecutive side and front walls of the aforesaid box in an internal region of the carton itself, a region which will become the perimetric surface of the box itself, in particular between the respective fold lines which delimit the opposite top walls and bottom walls of said box. In accordance with a further aspect of the present invention, each of the aforesaid cartons in the flattened condition? provided with two folding lines, one on an upper face and one on a lower face, however arranged offset from each other by a distance equal to the difference between the length and width of the box. So, to go and pick it up across the folding line, preferably the cardboard? fed and always positioned so that one of the two folding lines is the pi? as close as possible to the first sampling organ; if there? could not be guaranteed, a first option ? that the first drawing member is long enough to climb over the folding line even when the latter is? in the most distant, or, in a second option, pu? be provided for a further mobile carriage according to a further degree of freedom? linear in a direction orthogonal to the directions of development of the aforementioned two guides, so that the aforementioned first pick-up member is selectively movable also along the depth? of the aforementioned offices of the aforementioned unit? storage, to move forward an amount? default ? as the mutual position of the two fold lines ? note in advance? to reach and exceed the bending line even when ? arranged further apart.

In accordance with a further aspect of the present invention, the aforesaid plant has an arrangement substantially in the shape of an inverted U, or horseshoe, with the aforesaid area for introducing objects into the boxes in the centre, between the aforesaid feeding station and the aforesaid forming apparatus .

In accordance with a further aspect of the present invention , the aforesaid means for closing the back wall comprise, or consist of, means for automatically applying an adhesive tape or means for dispensing glue.

In accordance with a further aspect of the present invention, transport means are provided, associated downstream of the aforesaid forming apparatus, for transferring each box downstream; formed in a three-dimensional condition open towards the aforementioned object introduction station.

ILLUSTRATION OF THE DESIGNS

These and other aspects, characteristics and advantages of the present invention will become clear from the following description of embodiments, provided by way of non-limiting example, with reference to the accompanying drawings in which:

- fig. 1 ? a schematic plan view of a packaging plant according to the present invention

- fig.2 ? a block diagram of a control circuit of the plant of fig. 1;

- fig. 3 ? an axonometric view, schematic and partially sectioned, of the system in fig. 1.

- fig. 4 ? an axonometric view of a box that can be used by the system in fig. 1;

- fig. 5 ? a front view of a forming apparatus of the implant of FIG. 1;

- fig. 6 ? a rear view of the forming apparatus of fig.5; - fig. 7 ? a partially sectioned left side view of the forming apparatus of fig. 5;

- figures 8 to 11 are schematic representations of some operating phases of the forming apparatus of fig. 5;

- fig. 12 ? a left side view of an enlarged detail of the forming apparatus of fig. 5 in the operative phase illustrated in fig. 8;

- figs. 13a, 13b, 13c are schematic plan views of a forming device of the forming apparatus of fig. 5 under different operating conditions;

- figs. 14a, 14b are schematic side and front views of a closing device of the forming apparatus of fig. 5;

- fig. 15 ? a schematic front view of a closing station of the system in fig. 1,

It should be noted that in the present description the phraseology and terminology used, such as for example the terms horizontal, vertical, front, back, top, bottom, internal and external, with their variations, have the sole function of better illustrating the present invention with reference to the figures of the attached drawings and must not be used in any way to limit the scope of the invention itself, or the scope of protection defined by the attached claims.

Furthermore, those skilled in the art will recognize that certain dimensions, or features, in the figures may have been magnified, distorted, or displayed in an unconventional or non-proportional way to provide a more accurate version. easy understanding of the present invention. When dimensions and/or values are specified in the following description, the dimensions and/or values are provided for illustrative purposes only and must not be understood as limiting the scope of protection of the present invention, unless such dimensions and/or values are present in the attached claims.

For ease of understanding, identical reference numerals have been used wherever possible to identify identical commonalities in the figures. It should be understood that elements and features of one embodiment may be conveniently combined or incorporated into other embodiments without further specification.

DESCRIPTION OF SOME FORMS OF EMBODIMENT OF

PRESENT FOUND

Will it be done? now reference in detail to the possible embodiments of the invention, of which one or more? examples are illustrated in the attached figures by way of non-limiting example. Even the phraseology and terminology used here? for non-limiting example purposes.

With reference to figure 1, a packaging plant 10 according to the present invention, for packaging one or more objects 101 of various nature and size in boxes 11, includes:

a forming apparatus 100 for automatically forming the appropriately sized boxes 11;

a supply station 104 in which the objects 101, even just one, forming part, for example, of the same purchase order, or to be sent to the same addressee, are grouped together in batches or sets; an introduction station 105, in which the objects 101 of each lot are introduced, manually or automatically, into a given box 11 optimally sized according to the size and volume of the lot to be contained;

a closing station 106 to close the boxes 11 after the objects 101 have been introduced into them.

The forming apparatus 100 and the feeding stations 104, introduction 105 and closure 106 will be described later. forward in detail.

In the embodiment described herein, the introduction station 105 ? advantageously positioned in a central position between the feeding station 104 and the molding apparatus 100, according to an inverted U, or horseshoe, arrangement, so as to make it easier to use it. facilitates the transfer of the objects 101 into the respective box 11, for example manually by an operator P.

The 106 locking station ? arranged near the introduction station 105, for example set back with respect to it.

The plant 10 also comprises a unit? central control unit 120 (fig. 2), preferably of the programmable type, for the coordinated control of the apparatus 100 and of the stations 104, 105 and 106. The unit? central control 120 pu? possibly be connected, by any known means, or that sar? developed in the future, to a warehouse management system (WMS), which runs for example on a server 122, for the management of purchase orders issued by a plurality of customers by any means of communication, for example via the Internet, even if this invention is not limited to what?.

Each purchase order identifies the objects 101 that a customer has purchased at a given moment, which together define the same batch of objects 101, which will preferably be delivered to the same customer, or to a recipient indicated by him, in a suitable box 11 of appropriate dimensions, which according to one aspect of the present invention ? formed automatically by the forming apparatus 100 precisely on the basis of the size/volume of the batch of objects 101 to be introduced therein. In fact, the? one or more? objects 101 of a given order/batch, have a certain size, or overall volume, which ? very variable, so that each lot requires a specific box 11 of suitable dimensions, which must conveniently be the smallest? small as possible, to optimize both the storage spaces of the boxes 11 gi? packaged, and the subsequent shipment to the recipients, thus reducing? costs.

How will you see? more ahead, to satisfy the aforementioned need? and therefore to increase the versatility? of?system 10, as well as? to reduce the packaging times of each box 11, the forming apparatus 100 ? able to automatically form boxes 11 of different sizes starting from a plurality? of cartons 12 of a known type and of standardized dimensions. Typically, these cartons 12 are supplied in a flattened condition and have different dimensions from each other.

With the expression ?form a box? or ?forming of a box?, here and in the present description it is meant the operation on the basis of which, starting from a carton 12, the relative bottom is formed, ?shaping? and closing the lower flaps, the side and front walls of a box 11 are formed, leaving an upper opening available for introducing the objects 101.

This upper opening, in a closing operation of the box 11 following the aforesaid forming and the introduction of the objects 101 and any filling material, as better explained hereinafter, is closed by folding and closing the relative upper flaps. Power station 104 ? configured to contain, subdivided by lots, the various objects 101 to be packaged in the appropriate boxes 11. In the embodiments described here, the supply station 104 comprises a temporary store 107 (fig. 3) having for example the shape of a shelf provided of a plurality? of spaces 108, of the through type, arranged for example according to a matrix of rows and columns, with the rows at different heights. Each compartment 108 has a loading opening, for example positioned on a front wall of the temporary magazine 107 (on the right in fig. 1), from where? It is possible to insert the objects 101, and an opposite withdrawal opening, easily accessible by an operator P in charge of the introduction station 105. In each compartment 108, which has a horizontal support surface, the objects 101 can be temporarily positioned for the same batch, waiting to then be introduced into the corresponding boxes 11 in the introduction station 105.

The loading of the rooms 108 with the objects 101 can? be done both manually and automatically, for example by withdrawing the objects 101 themselves from another warehouse of the objects 101, of a known type and not shown in the drawings.

The temporary warehouse 107 and/or each compartment 108 can? be provided with at least one detection device 109 capable of detecting the presence and/or volume of each of the objects 101 and/or of each batch of objects 101 in each of the compartments 108.

The temporary warehouse 107 (fig. 1) can? also be equipped with one or more? display devices 111, of a known type, possibly positioned in correspondence with each compartment 108 to visually indicate to the operator P in charge of the introduction station 105 in which of the compartments 108 there are the objects 101 to be taken from the temporary store 107 and introduced into the corresponding box 11. The aforementioned display devices 111 can also display the sequence with which the compartments 108 must be unloaded by the operator P in charge of the introduction station 105 and which? synchronized with the automatic preparation sequence of the boxes 11 by the forming apparatus 100.

To do this, the feed station 104 can understand, moreover, a first unit? control unit 110, preferably of the programmable type, connected both to the detecting device 109 and to the display devices 111, and to the unit? central control 120.

Favorably, the preparation of the box 11 takes place in a synchronized and sequential manner with the completion of the batch of objects of the order. In the temporary warehouse 107 can there be more? complete lots and, according to the present invention, one envisages starting in sequence to form the first box 11 and in the temporary warehouse 107 it will come indicated or displayed the? associated lot of objects to be introduced in the box 11 in preparation when the same box 11 will be? ready. At the same time it is foreseen to start forming the box 11 for the subsequent order. This last box 11 will remain? in the forming equipment 100 until it will be? completed box 11 above. In alternative embodiments of the present invention, the supply station 104, instead of the temporary store 107, can comprise a transport member which conveys, automatically and in a coordinated way with the formation of the boxes 11, towards the introduction station 105, a plurality? of containers in each of which ? contained a different batch of objects 101. In this case, this invention can? provide that the information relating to the volume of the objects 101 to be packaged and/or the dimensions of the box 11 are processed and managed in such a way as to give the time necessary for the picking and sequential formation of the boxes 11, in particular providing, upstream of the station of introduction 105, a temporary accumulation warehouse, or buffer, of containers containing the objects 101 of each batch. In case, possibly, pu? there should also be an apparatus for automatically introducing objects into the boxes 11, for example of the type described in a related patent application for an industrial invention which the Applicant filed at the same time as the present patent application.

In accordance with one aspect of the present invention, each box 11 is formed automatically by the forming apparatus 100 starting, for example, from a plurality? of types of cartons 12 (fig. 3) of standardized dimensions, with each of which ? It is possible to form a box 11 having defined dimensions, in width, length and height, which define its maximum capacity.

For example, each carton 12 (figures 4 and 12) comprises a sheet pre-cut, folded and glued with a tab, or flap, K so as to form two walls flattened one against the other and suitable for being moved to assume a open three-dimensional condition such as to form a box 11, for example in the shape of a parallelepiped with a rectangular base having two front walls 114 and 116 and two side walls, or sides 113 and 115, spaced out by folding lines F. Each flattened wall of each carton 12 comprises first cuts G1 (fig. 12) which define four lower edges 117 (only two of which are visible in fig. 4), suitable for forming, by folding along a first crease line M1 (fig. 12), the bottom , or bottom wall, of a box 11, and second cuts G2 which define four upper flaps 118, suitable for forming, by folding along a second crease line M2, the upper or closing wall of the same box 11. Furthermore , each carton 12, on each of the two flattened walls, can possibly be optionally equipped with one or more? additional creasing lines N1, N2, so that it is possible to select at what height the upper flaps 118 are folded to close the box 11. Therefore, with the same carton 12 ? possible to make a box 11 having a height and therefore a selectable capacity, according to the creasing M2 or N1 or N2 chosen for folding,

Such cartons 12 supplied in a flattened condition are also referred to in the industry as "flattened pre-glued boxes".

The forming apparatus 100 (fig. 5) comprises a supporting structure 13 on which disposed, on a plane S, for example horizontal, a first unit? of storage 16 configured to house a plurality? of 12 cartons, typically of different sizes, how will it be? more described in detail below. Possibly, a second unit? of storage 17 of cartons 12 of different sizes can? be placed on a Q plane, parallel to the S plane, above the first unit? of storage 16.

In other embodiments of the present invention, not shown in the drawings, the forming apparatus 100 can include a single unit? of storage or a number of units? of storage greater than two, such as three, four, or more.

Given the substantial similarity? of the first unit? of storage 16 with the second unit? of storage 17, the following description will be? relative only to the first unit? of storage 16.

The first unit? storage unit 16 comprises a frame 18 (figures 5, 6 and 7) shaped so as to define at least two uprights 19, a substantially horizontal upper wall 20 (fig. 7) and a base 21, which together define a compartment 22.

In particular, the base 21 has a substantially horizontal lower part and an upper part shaped so as to define a plurality of of seats, or compartments, 24 each for a group of cartons 12. Typically, a plurality? of cartons 12 in flattened condition pu? be divided into groups, also on the basis of their respective sizes. These dimensions can be different from each other. Each group of cartons 12 ? positioned in a respective seat 24. Each seat 24 can, for example, house a group of cartons 12 of equal size, yes? that as a whole each seat 24 contains a group of cartons 12 in flattened condition of equal size to each other but different with respect to the size of a group of cartons 12 in flattened condition contained in another seat 24, as can be seen for example in figs. 3, 5 and 6).

Each seat 24 has a bearing surface 29, which can be inclined at an angle? for example between 0? and 90?, in particular preferably between 10? and 30?, with respect to the lower part of the base 21. Furthermore, each seat 24 has a side wall 30 substantially perpendicular to the support surface 29 and a front wall 31, which acts as a stop wall or limit switch for the cartons 12 and which ? essentially vertical. What? the cartons 12 are arranged on the support surface 29 in a repeatable and automatically recognizable reference position. In particular, the manual or automatic operator who loads the cartons 12 into each seat 24 pushes them until they abut against the front wall 31. In this way all the cartons 12 are flush with this front wall 31 and therefore, in the subsequent forming step, all the boxes 11 will have the front wall 114 or 116 in the same position.

In this way, once the cartons 12 have been inserted into a corresponding seat 24, they are inclined by the aforementioned angle ? with respect to a vertical plane and arranged with their faces substantially parallel to the wall 30, with the cardboard 12 more? internal in contact with the latter and the others packed on it.

In the example provided here, there are six seats 24, but it must be clear that they can also be in a number other than six, depending on the capacity to be given to each of them, on the overall space available for the forming equipment 100 and of the different formats of the cartons 12.

Overall, the 24 offices of the first unit? of storage 16 and of the second unit? of storage 17 are arranged at different heights, for example according to a matrix of rows and columns, with the rows at different heights.

Each seat 24 ? suitable for containing a suitable number of cartons 12, preferably of the same size, for example standardised, inclined and packed, with each of which ? possible to make a box 11.

For example, each carton 12 present in each location 24 can allow you to make boxes 11 with the same section in plan view but of different heights, how will it be? more described in detail below.

In possible embodiments, the seats 24 can be equipped with sensors configured to detect and verify a filling level of cartons 12 of the same seats 24 and supply a correlated signal, useful for example for the purpose of replenishing cartons 12.

Furthermore, the aforementioned seats 24 have a loading opening, for loading the cartons 12, and an opposite opening for picking up the cartons 12.

The different seats 24 communicate with each other in a common upper transfer space 25 (fig. 6).

Preferably, the cartons 12 are supplied in said seats 24 in a flattened configuration with the upper edges facing downwards. Advantageously, the layout of the units? of storage 16, 17 ? such as to allow maximum flexibility?; in fact, since? the cartons 12 are arranged with the upper flaps downwards in a similar way to what occurs in known manual picking and packaging stations, in case of need? the units? of storage 16, 17 can be used by the operator in the classic manual way.

The forming apparatus 100 also comprises a second unit? controller 123 (fig. 2), for example of the programmable type, and provided with a memory, in which, for each of the seats 24, information is stored on the types of cartons 12 present therein, for example information on length, width and height and one or more? capacity volumes obtainable for a corresponding box 11.

The forming apparatus 100 also comprises a forming device 34, which will be? described more further on in detail, configured to form a box 11 starting from a carton 12.

The first unit? storage device 16 also comprises a first device 33 for picking up the cartons 12, having the function of picking up one of the cartons 12 present therein from a selected seat 24, to bring it to the forming device 34.

The first pick-up device 33 comprises a horizontal guide 35 fixed to the upper part of the frame 18 externally to the compartment 22 (fig. 7) and extends substantially from one side of the latter to the other (fig. 5), in the direction of length, i.e. parallel to the lower part of the base 21, along a longitudinal, or horizontal axis, X.

On the horizontal guide 35 ? slidingly mounted a first trolley 36 connected, by means of connection means of a known type and not shown in the drawings, to a first electric motor 37 mounted on the horizontal guide 35 and configured to make it slide selectively, in both directions, i.e. to the right or to the left, parallel to the longitudinal axis X.

The first electric motor 37 ? controlled by the second unit? control 123 (FIG. 2).

The first pick-up device 33 also comprises a vertical guide 39 mounted on the first trolley 36 to slide together with it, outside the compartment 22, perpendicularly to the horizontal guide 35, between a rest or starting position, in which, for example, is it at one end? of the compartment 22 in correspondence with the forming device 34 and a final position in which it is on the opposite side of the compartment 22 with respect to the forming device 34.

On the vertical guide 39 ? slidingly mounted a second trolley 42 connected, by means of connection means of a known type and not shown in the drawings, to a second electric motor 43 mounted on the same vertical guide 39 and configured to make it slide selectively, in both directions, i.e. downwards or towards the top, along its own vertical axis Y, orthogonal to the longitudinal axis X. Also the second electric motor 43 ? controlled by the second unit? control 123.

On the second carriage 42 ? mounted a first pickup member 44 to pick up a selected cardboard 12, which can rotate around its own transversal axis Z, by a third motor 45 (fig. 7), controlled by the second unit? control 123.

As an alternative to the embodiments which provide for the guides 35, 39 and the relative carriages 36, 42, the first pick-up member 44 could be moved by a robotic device configured with at least two degrees of freedom? linear, possibly even a third degree of freedom? linear, and possibly a degree of freedom? angular.

The first pick-up member 44 extends from the second trolley 42 inside the compartment 22 in order to be able to interact with each carton 12 to be picked up, as it will be? more described in detail below.

For example, the first pickup member 44 comprises gripping elements, in this case pickup suckers 48 connected to a suction pump, of a type known per se? and not shown in the drawings, capable of selectively generating a vacuum, or a depression, between them and an outer surface of the cardboard 12 to be picked up.

The forming device 34 ? positioned adjacent to the unit? of storage 16 and 17 along the longitudinal axis X to be fed with the cartons 12, arranged in the seats 24, and configured to carry out the forming, or ?unfolding?, of the box 11 starting from the carton 12 in the flattened condition taken, for then proceed to close the bottom of the same by means of a closing device 67 which will come? described below, on a fund closure plan substantially coplanar to plan S, and thus provide? a box 11 with the bottom closed and open towards the top.

The forming device 34 ? able to be positioned, moreover, below the horizontal guide 35 so that when the vertical guide 39 is in the final position it is vertically aligned with it. In the final position, the first pickup member 44 of the unit? of storage 16 pu? delivering the picked box 12 to a second picking member 54, described in detail below, to then proceed with the forming with the aforementioned forming device 34. To feed a box 12 towards the closing device 67, for example coming from plane Q of the second unit? of storage 17, which is located on a lower floor? high compared to the S floor, or from the S floor of the first unit? storage unit 16, the forming apparatus 100 comprises a transfer device 52 configured to transfer the cardboard 12 picked up by the respective first pickup member 44 of the second unit? of storage 17 or of the first unit? of storage 16. The transfer device 52 comprises a vertical guide 53, in particular with linear development, to which ? slidably associated with the aforementioned second picking member 54 configured to associate with the cardboard 12 and connected to a fourth electric motor 55 configured to make it slide along the vertical guide 53.

In fact, therefore, the carton 12 is delivered by the first pick-up member 44 to the second pick-up member 54 which takes it stably. To this end, the second pick-up member 54 comprises an arm which extends transversally with respect to the vertical guide 53 and ? endowed with a plurality of gripping elements, for example gripping suckers 56 connected to a suction pump, of a type known per se? and not shown in the drawings, with a function similar to that of the pick-up suckers 48 of the first pick-up member 44.

In particular, the second drawing organ 54 ? mounted on a third carriage 57 movable on the vertical guide 53 to pass from a first position, or upper position, i.e. substantially higher? top of the plane Q (figs. 5 and 6), in which the passage of the cardboard 12 takes place from the first pickup member 44 of the second unit? storage device 17 to the second pick-up member 54, at a second or lower position, not shown in the drawings, i.e. substantially in the vicinity of the closing plane in which the passage of the ?unshaped? carton 12 takes place from the second withdrawal member 54 to the closure device 67.

In embodiments, the vertical guide 53 is mounted on a translation device 58 operated by a relative motor 59 (figs. 5, 6, 7, 14a, 14b). The translation device 58 ? suitable for selectively determining a horizontal translation motion of the linear guide 53 with respect to the bottom closing means 67.

In particular, this translation device 58 ? configured to allow an alternating linear movement of the vertical guide 53 along a direction essentially parallel to the aforesaid longitudinal or horizontal axis X, as schematically indicated by the arrow L for example in figs. 6 and 14b.

This additional horizontal movement of the linear guide 53 allows the position of the second pick-up member 54, and therefore of the carton 12, to be selectively adapted with respect to the closing device 67 to adapt to the possible different dimensions of the carton 11 obtained, as it will be? explained below. For example, the translation device 58 can include a transport member 58a, such as a wound belt, driven by the motor 59 and connected to the aforementioned linear guide 53. Also in this case, as an alternative to the embodiments which provide for the guide 53 and the relative carriage 57, the second pick-up member 54 could be moved by a robotic device configured with at least one degree of freedom? linear.

In the example provided here, the forming device 34 is directly associated with the transfer device 52 and ? movable integrally with it.

In the embodiment described here, this forming device 34 comprises at least one rotary lever member 60 (figs. 13a, 13b, 13c) rotatably mounted on a support block 61, by means of a pin 65.

The support block 61 in turn ? willing to a? extremity? of the second picking member 54. The lever rotating member 60 ? controlled in rotation by a fifth electric motor 62 controlled by the second unit? control 123.

The lever rotating organ 60 ? equipped with at least one gripping portion 63 adapted to selectively couple with one or more? parts of the aforementioned cardboard 12 to rotate the latter, as indicated by the arrow R in figs. 13a, 13b, 13c and determining an open three-dimensional condition of the aforementioned carton 12 defining the aforementioned box 11 (see operating sequence of figs. 13a, 13b, 13c). The gripping portion 63 can for example being a suction cup operated by a suction pump, to generate a vacuum, not shown in the drawings. If suitably controlled in a selective way, the vacuum circuit and/or the pump can be the same ones associated with the second drawing member 54.

The lever rotating organ 60 ? configured to pass by rotating from a starting position, where ? transversal to the second pickup member 54 (fig. 13a), to a coupling position (fig. 13b) in which ? in contact with the picked up cardboard 12 and effectively kept suspended by the second picking member 54. In this coupling position, the activation of the gripping portion 63 combined with a new rotation of the lever rotating member 60 from the coupling position to the starting position (fig. 13c) determines the opening of the carton 12 in virtue? of the articulation of the walls of the same around the respective folding lines.

? a closing device 67 is also provided (figs. 14a, 14b) to close the bottom of each box 11. The second picking member 54 transports the carton 12, once opened by the forming device 34, towards this closing device closure 67, thanks to the gripping action of the suction cups 56.

The closing device 67, which can? be of any known type, ? configured to rotate the four bottom walls and close them, for example by means of adhesive tape, or the application of glue, and thus form the bottom of the box 11 in a stable way, to move it subsequently, by means of transport means 68 (figs. 1, 3 ), towards the introduction station 105 (fig. 1), where ? the manual or automatic introduction of the objects 101 to be packaged is envisaged.

The closure device 67, schematically represented in figs.

14a and 14b, comprises for example a pair of rotating levers, or folders, 66 arranged opposite each other to rotate two respective bottom flaps 117 of the carton 12 once it has been opened (arrows M in fig. 14a). Each rotary lever 66 ? mounted on a respective support block 79. One of the two support blocks 79 ? coupled to the aforesaid transport means 68 which can be, for example , belts or the like, to determine the advancement along a sliding plane 82 (arrow C in fig. 14a). In the present case, the support block 79 which determines the advancement ? the rear one, thus acting as a pusher operated by the transport means 68. The rotating lever 66 mounted on the support block 79 coupled to the transport means 68 allows to adapt to the dimensions of the box 11 and, in particular, to process boxes 11 of different lengths . The closure device 67 also comprises a pair of contrast rollers 78, movable linearly between two positions, close and spaced apart (fig. 14b), to determine the rotation and fold of the remaining two bottom edges 117 (arrows E in fig. 14b ). In particular, each contrast roller 78 ? associated with a transversal movement guide 80 by means of a relative support 81.

After the first two bottom flaps 117 have been folded by the pair of rotary levers 66, ? the action of the pair of contrast rollers 78 is foreseen which are moved towards each other to fold the second pair of bottom flaps 117. After which, the box 11 with the bottom closed is moved by means of transport means 68 towards introduction station 105.

The closing device 67 can? be provided with adhesive tape applicator members, for example with a roller or the like, to apply the closing tape on the back wall once the second pair of bottom flaps 117 has also been rotated. The application of this adhesive tape can? be performed on the fly while the box 11 is transported by the transport means 68 towards the introduction station 105. If a tape application group is provided, it ? favorably configured so as to apply the tape centered along the center line of the box 11. Alternatively ? conceivable to foresee the dispensing of an adhesive before the closure of the second pair of bottom flaps 117. The adhesive tape can? be of the water-activated adhesive type.

Advantageously, thanks to the translation device 58 to which ? associated with the guide 53 ? It is possible to horizontally and selectively move the second picking member 54 and the associated forming device 34, consequently also translating the ?unshaped? carton 12, to adapt to the dimensions of the latter for the purpose of closing the wall of bottom, in particular to favor the positioning of the closing tape centered along the center line of the box 11. It is possible to process boxes 11 of different widths by keeping their center line fixed with respect to the closing device 67. In particular, it is possible to process boxes 11 of different widths. It is possible to form boxes 11 of different widths keeping as a fixed reference the center line of the box 11 where the tape for closing the back wall is applied even if the boxes 11 have different widths.

Possibly, before the introduction of the objects 101 in the boxes 11, ? the application of a label, or neck marker, on the box 11 is envisaged so that the same is uniquely associated with the batch of objects it contains and therefore with the associated order. This parcel marker is then used at a final labeling station, prior to shipment, to affix the consignee address.

In embodiments of the present invention, the introduction station 105 can? be automated and include a third unit? control unit 125 (fig. 2), connected to the unit? central control system 120 and configured to control the operation of the introduction station 105.

The 106 locking station ? positioned downstream of the introduction station 105 (fig. 1) and ? configured to receive the box 11 containing the objects 101 and close its upper part using the upper flaps 118 (fig. 15).

Optionally, the closing station 106 can comprises cutting members 69 configured to reduce the size of the box 11, in particular by lowering its height, before closing its upper part, for example along one of the creases N1 or N2.

Advantageously, the introduction station 105 or the closing station 106 can present optoelectronic acquisition means 77 (figs. 1 and 3) of the aforementioned box 11 and of the objects 101 contained therein, for example dimensions of the box and objects, in particular at least height, for the purposes of the subsequent resizing of the aforementioned box 11 by means of the of cutting 69. The latter are configured to automatically cut parts of the aforementioned box 11 on the basis of the aforementioned optoelectronic acquisition.

In particular, the cutting members 69 are configured to extend the second cuts G2 so as to lengthen each upper edge 118, thus to decrease the height of the box 11, as known in the art with the English term ?down-sizing? or ?put in height? the box 11, and therefore being able to close the box 11 to size.

The signal supplied by the optoelectronic acquisition means 77 can also be used to check if ? the objects have been introduced into the box 11. If the objects have been introduced? verified, then the method allows to advance the formed box 11 and into which the objects have been introduced towards the closing station 106. In addition, advantageously the method also allows to advance the next formed box 11 towards the introduction station 105 .

Furthermore, by means of the optoelectronic acquisition means 77 pu? also check that any filling material does not protrude from the box 11.

The closing station 106 can? furthermore comprise a vertical movement device 70, which comprises a horizontal support plate 71 sliding vertically on a bar 72, controlled by an actuator 73 between a raised position, shown in fig. 15, in which each box 11 is located after the objects 101 have been introduced into it, and a lowered position, represented with dotted lines in fig.

15, to selectively bring each box 11 down? packaged with the objects 101, on a conveyor member 75, therefore arranged at a lower level? low compared to where the introduction of the objects into the box 11 takes place, and suitable for transporting the box 11 selectively towards a warehouse, or a shipping station, of a known type and not shown in the drawings. The actuator 73 ? controlled by a fourth unit? control 126 connected to? unit? central control unit 120 (FIG. 2).

Favorably, the transporter member 75 ? willing to a level pi? down so that the outgoing flow of boxes 11 can pass under the unit? of storage 16, 17 and therefore can be common to pi? machines or systems of the type described herein. The direction of advance determined by the transport member 75 ? indicated by the arrow T in fig. 15 After box 11 ? been lowered and deposited on the conveyor member 75 by means of the vertical movement device 70, the upper flaps 118 are closed by means of a further closing device 85 comprising a pair of closing levers, or folders, 84 and a pair of rollers of contrast 85, shown here schematically and similar to those described using figs. 14a, 14b, however acting on the upper flaps 118. The closing levers 84 are selectively rotatable as indicated by the arrow Q in fig. 15. Furthermore, a first lever 84 (on the left in fig. 15) is? also movable linearly along the advancement direction T and a second lever 84 ? in a fixed position (on the right in fig. 15). The fact that the first lever 84 is mobile allows it to adapt to the dimensions of the box 11 and, in particular, to process boxes 11 of different lengths, similarly to the rotating lever 66 mounted on the mobile support block 79 shown in figs. 14a and 14b. Furthermore, the contrast rollers 85 are movable transversely to the feed direction T by means of a further transversal movement guide 86 to which they are associated by supports 87.

In particular, after the action of the cutting members 69 for height adjustment, the box 11 is made to advance to the right in fig. 15 from the transport member 75 until the first lever 84, on the left in solid line and in the center in broken lines in fig. 15, and the second lever 84 are in position to fold a first pair of upper flaps 118. After which, in this position of the box 11, the contrast rollers 85 intervene to determine the closure of two further upper flaps 118, concluding the closure sequentially of all the upper flaps 118, to then proceed with the application of the closing adhesive tape. In the event that a group of application of a closing tape is foreseen, it can? be favorably configured mobile because, following the ?down-sizing? operation, the application position of the upper tape might not necessarily be centered with respect to the center line of the box 11. Also in this case, as an alternative? conceivable to dispense a glue before closing the second pair of upper flaps. After which, as mentioned, the closed box 11 is definitively evacuated by the conveyor member 75.

The introduction station 105, or the closing station 106 can also comprise a filling material delivery device 76 (figs. 1 and 3) configured to introduce filling material, for example paper or air bags, into the box 11, to occupy at least partially the space inside the box 11 not occupied by one or more? objects 101.

The operation of the plant 10 described up to now, which substantially corresponds to the method according to the present invention, is the following. The unit general control system 120 receives from the warehouse management system (WMS), configured to receive and manage purchase orders, an order signal relating to a specific purchase order, which identifies the batch of objects contained therein.

The order signal includes, for example, a list of one or more? 101 items ordered and pu? furthermore comprise information on the volume of each product 101 present in the list and/or the overall volume, or volumetric encumbrance, of the objects 101 of the same purchase order. In possible implementations, this signal pu? include, additionally or alternatively, information relating to the dimensions of the box 11 suitable for containing the determined group of objects 101 of the order, in particular length, width and height. As also explained below, this signal can? be used to correlate a capacity? containment of the corresponding box 11 in open three-dimensional condition, in particular length, width and height, with a volumetric encumbrance of the determined lot of one or more? objects 101 to be introduced into said box 11 so as to automatically identify and withdraw the corresponding carton 12 to be withdrawn. Subsequently, in a first phase in the feed station 104, the different batches of articles 101 are prepared, divided one from the other, each belonging to a specific purchase order and each batch ? inserted in one of the rooms 108 of the temporary warehouse 107.

Alternatively, in the event that the supply station 104 is loaded in manual mode, the order signal can be transmitted, for example, to a control device such as a computer, a tablet, or a smartphone supplied to the assigned personnel, so that it takes one or more objects 101, for example from an object store, and place them in the compartment 108 of the temporary store 107.

In embodiments of the present invention, if the aforementioned order signal contains information on the volume of one or more? objects 101 and/or information on the dimensions, in particular length, width, height, of the box 11 suitable for containing the determined group of objects 101, can be sent parallel to the second unit? of control 123 which on the basis of this controls the selection of a carton 12 for the realization of the box 11 of capacity? coordinated, in time sequence.

Favorably, in possible implementations the order signal is processed by crossing the information on the volumetric size of the batch of objects 101 with information concerning the three dimensions of the box 11, i.e. length, width, height, in order to select the box 11 pi? suitable.

In other embodiments of the present invention, ? expected to send? information on the volume of? one or more? objects 101 detected by the detection devices 109 of the temporary warehouse 107.

Then, in a second step, the forming apparatus 100 automatically prepares one box 11 at a time, starting from a carton 12 selected from a plurality of boxes. of different cartons 12 available, depending on the volume of the specific batch of objects 101 to be introduced into the box 11.

In particular, for example, the second unit? control 123 receives information from? unit? general control 120, or from the first unit? control 110, on the volume of? one or more? objects 101 which constitute the batch to be packaged in a certain box 11 to be formed.

The second unit? of control 123 compares the value of the volume with a plurality? of memorized volumes corresponding to the plurality? of cartons 12 present at that moment in the seats 24 and commands the first pick-up member 44 of the pick-up device 33 to pick up the selected carton 12.

If the carton 12 to be taken ? out of stock, then the procedure can? envisage taking the larger cardboard 12, preferably more? close to those of the initially selected carton 12, on the basis of a logic of optimization of the operating cycle. The dimensions of the box 11 obtained from this larger cardboard 12 can then be adjusted, for example by means of a down-sizing procedure and possibly by inserting an adequate quantity of of filling material.

The first drawing organ 44 (figures 5 and 6) ? moved along the horizontal guide 35 from the starting position to the final position and along the vertical guide 39 to position itself in the vicinity of the selected group of cartons 12 on a corresponding seat 24 and then pick up the carton 12 closest? outside the group.

Furthermore, the first drawing organ 44 ? rotated around its transversal axis Z to assume an inclination corresponding to the inclination of the cartons 12 which ? equal to the above angle ? (Fig.8).

Optionally, the sampling device 33 can comprise optical sensors or the like, of a known type and not shown here, which are configured to detect the inclination of the cartons 12 and therefore adapt the inclination of the first picking member 44 to the inclination detected when this does not correspond to the nominal one of the ?corner ?.

The association of the first pick-up member 44 with the cardboard 12 takes place thanks to the pick-up suckers 48 operated by a suction pump, to generate a vacuum, not shown in the drawings. Advantageously, the first pick-up member 44 is associated with the cardboard 12 (fig. 13) straddling a folding line F, and possibly in a region included in height between the creasing lines M1 and M2, to prevent the cardboard 12 from collapses during the subsequent handling phases, in particular when it ? positioned horizontally.

Favorably, the box 12 is picked up with the upper flaps 118 facing downwards and subsequently, as explained below, in the pick-up movement by the first pick-up member 44 and delivery to the second pick-up member 54, the box 12 is rotated in so as to find themselves with the upper edges 118 pointing upwards (fig. 12).

In particular, the carton 12 ? extracted from the seat 24 (fig. 9) by means of combined movement of the first sampling member 44 along the longitudinal or horizontal axis X, the vertical axis Y and around the transversal axis Z, to position it horizontally (fig. 10) .

The first drawing organ 44 ? then moved on the horizontal guide 35 along the upper transfer space 25 and further rotated to be brought to a substantially vertical position (fig. 11) and with the lower flaps 117 of the box 11 facing downwards in correspondence with the initial position, in which the carton 12 ? transferred to the second picking organ 54. The carton 12, both in the case in which it is picked up from a seat 24 of the first unit? of storage 16 and in the case in which it is taken from a seat 24 of the second unit? storage device 17, is delivered to the second picking member 54 which transfers it downwards towards the closing device 67, after forming by means of the forming device 34 described above. This downward transfer takes place thanks to the transfer device 52, which, after the carton 12 is been formed by the forming device 34, moves on the vertical guide 53 carrying with it? the second pickup member 54 and the same formed cardboard 12 coupled thereto. Moreover, thanks to the translation device 58, also the guide 53 can favorably? be selectively translated horizontally alternately from and towards the subsequent closure device 67, as indicated for example by the arrow L in Figs. 6 and 14b, adapting to the width of the box 11 for the purposes of correct centered positioning of the box 11 itself with respect to the application of the tape.

In this way, box 11 ? created automatically while a possible operator can? be free to carry out other actions, for example to carry out, in the introduction station 105, the packaging of another batch of objects 101 in another box 11 previously formed. Furthermore, advantageously, the box 11 will not be n? oversized n? undersized allowing cos? to optimize space and costs.

The forming equipment 100 can? be supplied with the cartons 12 both manually, by assigned personnel, and in an automated way, for example by means of a suitable machine, for example a robot, of a known type and not shown in the drawings.

In a subsequent third operating phase, in the introduction station 105 (fig. 1) the batch of objects 101 prepared in the aforementioned first phase are introduced into the box 11 prepared in the aforementioned second phase, under the control of the third unit? of control 125, coordinated by the unit? of central control 120. Advantageously, with the present invention while the objects 101 of a lot associated with a determined order are introduced into the box 11, it is already? the box 11 of the order following the given order is formed and the box 11 of the order prior to the given order is closed at the same time. The operator only has to introduce the objects of the lot associated with the given order into the box 11, without worrying about forming and closing the boxes 11 of the next and previous order, since these operations take place automatically in time overlap.

The procedure foresees that the third phase is carried out in a time interval which ? at least partially superimposed on the time interval necessary for the first phase to prepare the batches of objects 101.

Practical experiences carried out by the Applicant have shown that the time in which a box 11 ? formed and made available by the forming equipment 100 ? substantially equal to the time required to prepare each batch of 101 items.

In this way, advantageously, the dead times between the packaging of objects 101 relating to one purchase order and the following one are reduced or even eliminated.

In fact, an operator in charge of packaging, at a given moment, will have? available for a given purchase order/batch of one or more? objects 101, a? associated box 11 whose capacity? ? coordinated with the volume of the objects 101. Therefore, the operator does not have to deal with the estimation and choice of the cardboard 12 and not even with its box-like conformation 11. Pu? provision should be made for indicating to the operator P, for example by means of the display devices 111, from which compartment 108 to take the objects 101 to be packaged in the box 11 provided at that given moment. In this way ? possible to avoid introducing 11 incorrect objects 101 into a box, i.e. corresponding to another purchase order.

The cartons 12 made available by the forming apparatus 100 in the first phase are suitable for making boxes 11 with a capacity range of 100 large enough to adapt to the range of objects 101 of the different purchase orders managed by the plant 10.

The aforementioned second phase provides that the second unit? control 123 monitors, at pre-established intervals, the quantity? of cartons 12 present in the forming apparatus 100 to send a replenishment signal in the event that the number of cartons 12 in each seat 24 drops below a certain predetermined number.

In the first stage, ? planned to deposit, preferably in each compartment 108, the? One or more? 101 items of a single order. The second unit? of control 123 stores the correspondence between the purchase order and the contents of the corresponding compartment 108, or possibly more? rooms 108, in which the objects 101 were temporarily deposited.

Can? be expected to detect the volume of? one or more? objects 101 deposited in the compartment 108, individually and/or as a whole and this information on the volume can be sent to the second unit? control 123 to select the correct carton 12.

The volume information detected by the detection devices 109 can integrate the? information already? present in the signal? order, or be used by the second unit? control 123, for example, to verify the correspondence between the expected volume, i.e. the one indicated by the order signal and the volume actually detected by the detection devices 109.

In embodiments, the second unit? of control 123 compares the information of the total volume of one or more? objects 101 with the information of a predetermined series of volumes memorized in its memory, each associated with a box 11 and a corresponding box 12 of coordinated dimensions and selects the box 12 corresponding to the volume range which includes the volume of one or more objects 101.

In the case of more of? an interval of volume including the value of volume of? one or more? objects 101 potentially suitable, the second unit? of control 123 selects the carton 12 with which ? it is possible to make the box 11 with a smaller volume.

For example, the second unit? control 123 pu? compare the volume detected of? one or more? objects 101 with the volumes of the boxes 11 obtainable from the cartons 12 present at a given moment in the apparatus 100 to select the one with the smallest dimension? suitable.

Once the second unit? control 123 has determined the suitable carton 12, it commands the first pick-up device 33 to move into the corresponding seat 24, pick up the carton 12 and transfer it to the forming device 34.

In a subsequent fourth operating step, in the closing station 106 (figures 1 and 15) the box 11 is closed, eventually the parcel marker is affixed if not applied before the introduction of the objects and selectively sent to a warehouse, or a shipping station under the control of the fourth unit? of control 126, coordinated by the unit? central control 120.

? It is clear that modifications and/or additions of phases or parts can be made to the packaging method and plant 10 described up to now, without thereby departing from the scope of the present invention as defined by the claims. ? It is also clear that, although the present invention has been described with reference to specific examples, an expert in the art could to produce other equivalent forms of packaging processes and systems, having the characteristics set forth in the claims and therefore all falling within the scope of protection defined therein.

In the claims which follow, the references in brackets have the sole purpose of facilitating the reading and must not be considered as limiting factors as regards the scope of protection defined by the claims themselves.

Claims (13)

1. Packaging process for packaging one or more? objects (101) in boxes (11), said method comprising: - provide one or more objects (101) grouped into respective lots, each lot being associated with a respective purchase order; - prepare at least one? unit? of storage (16, 17) comprising a plurality? of cartons (12) in flattened condition of different sizes; - choose, among the lots supplied, a lot to be packaged in accordance with a given production time schedule; - withdraw from that at least one? unit? of storage (16, 17) a carton from said plurality? cartons (12) in flattened condition, by picking means (44, 52); - opening the taken cardboard (12) to form a box (11) open at the top having side (113, 115) and front (114, 116) walls and a bottom wall, by means of forming means (34); - closing the back wall, by means of closing means (67); - supplying the box (11) open at the top to an introduction station (105); - introducing, into said introduction station (105), the selected batch of objects (101) into said box (11) open at the top; - close the upper opening of said box (11) e - transferring the closed box to further processing stations, or to shipping; wherein said removal of said carton (12) in flattened condition ? carried out on the basis of an automatic selection of a specific cardboard (12) in a flattened condition between said plurality? of cartons (12) in a flattened condition of different dimensions, in which a capacity is correlated? containment of the corresponding box (11) in an open three-dimensional condition, obtained with the opening of said carton (12), with a volumetric size of the selected batch of objects (101) to be introduced into said box (11) so as to be taken from said at least one? unit? of storage (16, 17) the carton (12) whose open box (11) offers a volume that more? approaches the batch volume to be introduced. 2. Process as in claim 1, characterized in that it provides for synchronizing an expected preparation completion time of a specific batch of one or more? objects (101) and correlate the? volumetric size of one or more? objects (101) of said specific lot with the operations foreseen for the removal of the carton (12) from said at least one unit? of storage (16, 17), the opening of the cardboard (12) taken to form the box (11) open at the top and the closure of the bottom wall. 3. Process as in claim 1 or 2, characterized in that the step of introducing, into a box (11) already? formed and closed on the bottom, one or more? objects (101) of a specific lot ? carried out in at least partial temporal overlap with one or more? of the operations envisaged for the withdrawal of the subsequent carton (12) from said at least one?unit? of storage (16, 17), the opening of said cardboard (12) taken to form the following box (11) open at the top and the closure of the relative bottom wall. 4. Process as in any one of claims 1 to 3, characterized in that it provides for the supply of a signal containing information correlated with the volumetric size of the determined batch of one or more? objects (101) to be introduced into said box (11) and possibly also the dimensions of a coordinated carton (12) and to associate, for the purposes of said automatic withdrawal, said information contained in said signal to a specific carton (12) of a plurality? of cartons (12) in a flattened condition, grouped into predefined groups on the basis of respective dimensions related to the capacity? containment of said boxes (11) in an open three-dimensional condition obtainable from each of said cartons (12). 5. Process as in any one of claims 1 to 4, wherein each carton (12) in a flattened condition is supplied in a given pick-up position so as to expose a fold line (F) between two walls to the outside main consecutive lines of said carton (12) adapted to respectively define a side wall, or side (113, 115), of said box (11) and a front wall (114, 116) of said box (11) and in which the withdrawal automatic of a respective carton (12) ? carried out by applying a gripping force on both surfaces astride said folding line (F), so as to keep said cardboard (12) in a flattened condition during the automatic withdrawal phase. 6. Packaging plant (10) to package one or more? objects (101) in boxes (11), said packaging plant (10) comprising: a feeding station (104) of one or more? objects (101) grouped into respective lots, each lot being associated with a respective purchase order in accordance with a given production time schedule; an introduction station (105) to introduce into a box (11) one or more? objects (101) of a certain lot; a closing station (106) for closing to size and transferring said box (11) towards further processing, or towards shipment; characterized in that said packaging plant (10) also comprises a forming apparatus (100) configured to carry out both an automatic removal of a corresponding carton (12) in a flattened condition, and a subsequent automatic forming of said carton ( 12) in an open three-dimensional condition defining said box (11) with upper opening, and the closure of the bottom wall of said box (11), wherein said forming apparatus (100) ? configured to carry out said automatic withdrawal of said corresponding carton (12) in a flattened condition on the basis of an automatic selection of said carton (12) from a plurality cartons (12) in flattened condition of different dimensions present in a unit? storage (16, 17), in which a? unit? control (120) ? configured to correlate a capacity? containment of the corresponding box (11) in an open three-dimensional condition, obtained with the opening of said carton (12), with a volumetric size of the selected batch of objects (101) to be introduced into said box (11) so as to be taken from said at least one? unit? of storage (16, 17) the carton (12) whose open box (11) offers a volume that more? approaches the batch volume to be introduced. 7. Plant as in claim 6, wherein said unit? control (120) ? configured to synchronize an expected completion time of preparation of a specific batch of one or more? objects (101) and correlate the? volumetric size of one or more? objects (101) of said specific lot with the operations foreseen for the removal of the carton (12) from said at least one unit? of storage (16, 17), the opening of the cardboard (12) taken to form the box (11) open at the top and the closure of the bottom wall. 8. Plant as in claim 6 or 7, wherein said unit? control (120) ? configured to synchronize? introduction, in a box (11) already? formed and closed on the bottom, of one or more? objects (101) of a given lot so that said introduction of objects (101) into a box (11) is in at least partial temporal overlap with one or more? of the operations foreseen for the removal of the following carton (12), the opening of the carton (12) taken to form the following box (11) open at the top and the closure of the relative bottom wall. 9. Plant as in claim 6, 7 or 8, wherein said unit? control (120) ? configured to provide a signal containing information correlated with the volumetric size of the given lot of one or more? objects (101) to be introduced into said box (11) and possibly also the dimensions of a coordinated box (11) and to associate, for the purposes of said automatic withdrawal, said information contained in said signal to a specific carton (12) of a plurality? of cartons (12) in a flattened condition, grouped into predefined groups on the basis of respective dimensions related to the capacity? containment of the boxes (11) in an open three-dimensional condition obtainable from each of said cartons (12). 10. Plant as in any one of claims 6 to 9, wherein said forming apparatus (100) comprises: said at least one unit? of storage (16, 17), which ? provided with seats (24) which communicate with each other in a common upper transfer space (25) and each suitable for housing, arranged on a corresponding support surface (29), a respective group of cartons (12); a first pickup member (44) positioned inside said unit? storage (16, 17) to fit into said seats (24) and provided with one or more? gripping elements (48) configured to selectively grip in a stable way a respective cardboard (12) in a flattened condition, which first picking member (44) ? associated with two carriages (36, 42) slidably positioned on two respective linear guides (35, 39) installed on said unit? of storage (16, 17), of which a first (35) horizontal and a second (39) vertical, so that said first pick-up member (44) is movable in at least two degrees of freedom? linear, respectively in height and length along said guides (35, 39) associated with said unit? of storage (16, 17), in which, moreover, said first withdrawal member (44) ? associated with a drive member (45) configured to rotate said first pickup member (44) about its own axis of development; a second pickup member (52) configured to cooperate with said first pickup member (44) to receive said cardboard (12) in a flattened condition (12), which second pickup member (54) ? equipped with one or more gripping elements (56) and ? mounted on a respective carriage (57) slidably positioned on a linear guide (53) arranged vertically in said unit? of storage (16, 17); forming means (34) associated with said second picking member (54) and provided with one or more? rotating lever elements (60) equipped with one or more? gripping portions (63) suitable for selectively coupling with one or more? parts of said carton (12) to rotate the latter and determine an open three-dimensional condition of said carton (12) defining said box (11); And bottom closing means (67) configured to close the bottom of said box (11). 11. Plant as in claim 10, wherein said unit? control (120) ? configured both to selectively control, directly or indirectly, the linear movement of said two carriages (36, 42) along said linear guides (35, 39), and to operate said drive member (45) to rotate said first control member pick-up (44) around said development axis, so as to overall cause a combined motion of said first pick-up member (44) along a resulting trajectory that is at least partially curvilinear, so that a flattened carton (12) taken from a respective group of inclined cartons (12) can rotate to release itself from said group of cartons (12) and be positioned substantially horizontally in said upper transfer space (25) common to said seats (24 ), then be linearly transferred towards said second pick-up member (54) and be rotated again to be delivered to said second pick-up member (54). 12. Plant as in claim 10 or 11, wherein said one or more? gripping elements (48) of said first picking member (44) are configured to apply a gripping force on both sides astride a folding line (F) between two consecutive main walls of said cardboard (12) suitable for respectively defining a side wall, or side, of said box (11) and a front wall of said box (11), so as to keep said carton (12) in a flattened condition during the automatic removal step. 13. Plant as in claim 10, 11 or 12, wherein said linear guide (53) is mounted on a translation device (58) operated by a relative motor (59) to selectively determine a horizontal translation motion of said linear guide (53) with respect to said bottom closing means (67).