AU2013344833B2

AU2013344833B2 - A packaging assembly

Info

Publication number: AU2013344833B2
Application number: AU2013344833A
Authority: AU
Inventors: Sam WALLS
Original assignee: ADAPTAPACK Pty Ltd
Current assignee: ADAPTAPACK Pty Ltd
Priority date: 2012-11-14
Filing date: 2013-11-14
Publication date: 2017-03-23
Anticipated expiration: 2033-11-14
Also published as: AU2013344833A1; NZ706944A; WO2014075151A1

Abstract

A packaging assembly (1) having a frame (2) operatively associated with a first conveyor (3) and a second conveyor (4). The first conveyor (3) being adapted to deliver products (100) to said assembly and defining a product loading plane (AA). The second conveyor (4) being adapted to deliver cartons (6) to said assembly and defining a carton loading plane (BB). The cartons having a base and side walls extending upwardly from said base to an open end spaced from said base and adapted to receive said products in use. A tilt member (20) is operatively associated with said carton conveyor. The tilt member adapted to receive a said carton at a predetermined location along said carton conveyor, and move said carton from the carton loading plane (BB) to a product input plane (CC). A first arm (30) having a first loading magazine (32) to receive in use product from said product conveyor. A second arm (40) having a second loading magazine (42) to receive in use product from said product conveyor. The first and second arms being spaced apart to permit simultaneous operation of said arms. The arms being operatively associated with each other, to permit consecutive loading of product into said respective magazines and to deliver said magazines consecutively to said opening of respective said cartons located consecutively at said product input plane.

Description

WO 2014/075151 PCT/AU2013/001330 1

A PACKAGING ASSEMBLY

Field [0001] The present invention relates to a packaging assembly and in particular to an automated packaging assembly to handle packaging of different products in a confined space.

Background [0002] Most products sold throughout the world are packaged prior to transport and sale.

Many products are packaged in cartons, pouches, trays or the like before product distribution. To make that packaging, a carton blank is typically fed into a packaging machine by an operator. The carton blank is erected into the desired carton shape ready for transferral to a loading station. At the loading station, an operator (or a robot) places product into the carton in a specific packaging layout. Typically, the carton is positioned on a horizontal surface (the X axis) and loaded from above. That is, vertical loading along the Y axis.

[0003] Vertical packaging machines require dedicated product accumulation. That is, the packaging machine creates substantial product back log waiting to be packed and this makes them slow, costly and labour intensive. Typically, existing packaging/loading machines also have a large footprint in a factory and are not easily adaptable to changing requirements of customers in respect of products, carton and product shapes and sizes. Existing machines are also typically single pick and place units packing products into a carton individually. Also flat packaging machines without vision sensors require pre-layer assembly before picking. Flat packaging machines with vision sensors require valuable floor space for separate carton erection. Further, existing packaging/loading machines typically operate only in a single direction.

[0004] Accordingly, angled packaging has been developed. However, existing angled packaging machines have been found to be time consuming because a robot individually places product into a carton. It would be advantageous to have products pre-stacked prior to packaging in a carton and to use more than one robot. PCT/AU2013/001330 WO 2014/075151 ..2 [0005] Accordingly, there is a need to increase packaging accuracy, increase packing speed, pack products of any shape and size and pack complex configurations.

Object of Invention [0006] It is an object of the present invention to substantially overcome or at least ameliorate one or more of the disadvantages of the prior art, or to at least provide a useful alternative.

Summary of Invention [0007] There is firstly disclosed herein a packaging assembly having: a frame operatively associated with a first conveyor and a second conveyor, said first conveyor being adapted to deliver products to said assembly and defining a product loading plane, said second conveyor being adapted to deliver cartons to said assembly and defining a carton loading plane, said cartons having a base and side walls extending upwardly from said base to an open end spaced from said base and adapted to receive said products in use; a tilt member operatively associated with said carton conveyor, said tilt member adapted to receive a said carton at a predetermined location along said carton conveyor, and move said carton from the carton loading plane to a product input plane, a first arm having a first loading magazine to receive in use product from said product conveyor; a second arm having a second loading magazine to receive in use product from said product conveyor; said first and second arms being spaced apart to permit simultaneous operation of said arms; said arms being operatively associated with each other, to permit consecutive loading of product into said respective magazines and to deliver said magazines consecutively to said opening of respective said cartons located consecutively at said product input plane.

[0008] Preferably, said product input plane is located at an acute angle to a vertical axis.

[0009] Preferably, said product loading plane is located in a substantially horizontal plane.

[0010] Preferably, said product loading plane is located at an acute angle to a horizontal plane. PCT/AU2013/001330 WO 2014/075151 3 [0011] Preferably, said carton loading plane is located in a substantially horizontal plane.

[0012] Preferably, said carton loading plane is located at an acute angle to a horizontal plane.

[0013] Preferably, said product conveyor is located substantially parallel to said carton conveyor.

[0014] Preferably, said product· conveyor is located substantially perpendicular to said carton conveyor.

[0015] Preferably, said conveyors are adapted to move in both directions along their respective planes.

[0016] Preferably, said first and second arms are robots.

[0017] Preferably, said robots are six or seven axis robots.

[0018] Preferably, said robots are mounted to said frame.

[0019] Preferably, said robots are spaced apart along both a horizontal and vertical axes to permit in use simultaneous operation.

[0020] Preferably, including means to apply an adhesive to said base to secure said base together.

[0021] Preferably, each said opening of each said carton includes one or more flaps, the assembly including means to apply an adhesive to said one or more flaps to seal said carton.

[0022] Preferably, said tilt member is mounted to said frame.

[0023] Preferably, said tilt member is pivotally attached to said frame.

[0024] Preferably, said tilt member includes an elongate bar extending from a tilt member mount across said carton conveyor, said bar in use being movable from the carton loading plane to the product input plane, and adapted to tilt the opening of a said carton to present said PCT/AU2013/001330 WO 2014/075151 4 opening to said magazines to receive said product, said bar returning said carton to said carton loading plane once said carton has been loaded with said products.

[0025] Preferably, including actuation means to move said bar.

[0026] Preferably, said actuation means includes one or more motors.

[0027] Preferably, including a sensor to activate said actuation means when a carton is located at the predetermined location.

[0028] Preferably, said tilt member includes a conveyor adapted in use to be moved to the product input plane.

[0029] Preferably, each said loading magazine includes a pair of gripping plates separated by a pusher plate, and actuation means, the actuation means being adapted to move said gripping plates towards and away from each other and to move said pusher plate in a perpendicular direction to said gripping plates in use, to permit positioning of said products within said magazine and to move said products from said magazine into a said carton.

[0030] Preferably, each said loading magazine includes suction means.

[0031] Preferably, said actuation means includes one or more motors.

[0032] Preferably, said arm includes means to move said magazines with respect to an end of said arm.

[0033] Preferably, said assembly is adapted to permit reverse flow packing.

Brief Description of Drawings [0034] A preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings, wherein: [0035] Figure 1 is a plan view of a packaging assembly of an embodiment of the present invention; WO 2014/075151 PCT/AU2013/001330 5 [0036] Figure 2 is a side view of Figure 1; [0037] Figure 3 is an end view of Figure 1; [0038] Figure 4 is an end view of a packaging assembly of another embodiment of the present invention showing robots 1 and 2 in a first position; [0039] Figure 5 is a plan view of Figure 4; [0040] Figure 6 is a side view of Figure 4; [0041] Figure 7 is another end view of Figure 4; [0042] Figure 8 is an end view of a packaging assembly of another embodiment of the present invention showing robot 1 in a second position loading product into the magazine; [0043] Figure 9 is another plan view of Figure 8; [0044] Figure 10 is another side view of Figure 8; [0045] Figure 11 is another end view of Figure 8; [0046] Figure 12 is an end view of a packaging assembly of another embodiment of the present invention showing robot 1 in a third position loading product into the magazine; [0047] Figure 13 is another plan view of Figure 12; [0048] Figure 14 is another side view of Figure 12; [0049] Figure 15 is another end view of Figure 12; [0050] Figure 16 shows a further embodiment of the present invention; [0051] Figure 17 shows a further embodiment of the present invention; PCT/AU2013/001330 WO 2014/075151 6 [0052] Figure 18 shows a further embodiment of the present invention; [0053] Figure 19 shows a further embodiment of the present invention; [0054] Figure 20 shows a further embodiment of the present invention; and [0055] Figure 21 shows a further embodiment of the present invention.

Description of Embodiments [0056] There is disclosed herein a packaging assembly 1 having a frame 2 operatively associated with a first conveyor 3 and a second conveyor 4. The first conveyor 3 is adapted to deliver products 100 to the assembly 1 and defines a product loading plane AA and is the product conveyor. The second conveyor 4 is adapted to deliver cartons 6 to the assembly 1 and defines a carton loading plane BB and is the carton conveyor. The conveyors 3,4 could be stand-alone conveyors or included as part of the assembly 1. There could also be more than two conveyors in use. The frame 2 could be of any shape however in the preferred form would be generally rectangular and having a series of interconnecting support beams as best seen in Figures 2 and 3. The frame 2 would be adapted to rest on a surface 10 and could include one or more adjustable feet 11 or the like. The conveyors 3,4 could also include such feet 11. The cartons 6 would be of the typical type having a base and side walls extending upwardly from the base to an open end spaced from the base and adapted to receive products 100. The carton 6 includes one or more flaps 12 at the opening which can be used to close off the opening to seal products 100 within the carton 6. A tilt member 20 is operatively associated with the carton conveyor 4 and adapted to receive a carton 6 when a carton 6 reaches a predetermined location along the carton conveyor 4 to move the carton 6 from the carton loading plane BB to a product input plane CC. In the preferred embodiment, the carton loading plane BB would be a horizontal plane however the plane BB could be at any angle to a horizontal axis XX or vertical axis YY depending upon the factory space and products 100 to be packaged. The product input plane CC in the preferred embodiment would be located at an acute angle X to the vertical axis YY. However it could also be at any angle depending upon operational circumstances. A first arm 30 in the form of a first robot has a first loading magazine 32 at one end 33 to receive product 100 from the product conveyor 3. A second arm 40 in the form of a second robot having a second loading magazine 42 at a respective end 43 is also included to PCT/AU2013/001330 WO 2014/075151 7 also receive product 100 from the product conveyor 3. The two robots 30,40 are spaced apart to permit simultaneous operation and consecutive loading of product 100 as best seen in Figure 1. In the preferred embodiment, the robots 30,40 would be spaced in all directions. The robots 30,40 are operatively associated with each other to permit consecutive loading of product 100 into their respective magazines 32,42 and to consecutively deliver that product 100 via their magazines 32,42 to an opening of a carton 6 that is located at the input plane CC. In a preferred embodiment the first magazine 32 would be loaded with product 100 and moved by the robot 30 vertically downwards to the product input plane CC. The second magazine 42 would move above the first magazine 32 to be filled. It would then follow vertically downwardly when filled. When loading each magazine 32,42 they are tilted at various angles with respect to the robots 30,40 by rotating means at the ends 33,43 to facilitate optional loading of product 100 from the product conveyor 3. This allows building up of product 100 from a comer and use of gravity to assist loading. The magazines 32,42 can move in various directions to accommodate product 100 stacking. The magazines 32,42 could also include vacuum suction means (not shown) or the like to assist with securing the product 100.

[0057] As can be seen in the drawings the conveyors 3, 4 could be located in various positions about the frame 2. For example, the conveyors 3,4 could be located substantially parallel to each other or substantially perpendicular to each other or at various angles with respect to each other. This will allow retro fitting to existing systems. In a preferred embodiment, the tilt member 20 is mounted to the frame 2 and includes an elongate bar 50 extending from a mount 52 across the carton conveyor 4. The bar 50 in use being movable from the carton loading plane BB to the product input plane CC tilting the opening of a carton 6 to present the opening to the loading magazines 32,42 to receive the product 100. The bar 50 returning the carton 6 to the carton loading plane BB once the carton 6 has been filled with product 100. In a preferred embodiment, the tilt member 50 would be pivotally attached to the frame 2 and include one or more actuation means 53 including motors 53 and sensors. The sensors (not shown) determine when a carton 6 has reached the predetermined location along the carton conveyor 4. In another embodiment, the tilt member 20 includes a conveyor (not shown) which is operatively associated with the carton conveyor 4. The tilt conveyor upon receipt of a carton 6 tilts itself to the product input plane CC presenting the carton 6 to the magazines 32, 42 to load product 100. Once the carton 6 is full of product 100 the tilt conveyor returns to align with the carton conveyor 4 and off loads the Ml carton 6. PCT/AU2013/001330 WO 2014/075151 8 [0058] The loading magazines 32,42 in a preferred embodiment include a pair of gripping plates (not shown) separated by a pusher plate (not shown). Actuation means (not shown) is provided to move the gripping plates towards and away from each other and to move the pusher plate in a perpendicular direction to the gripping plates to position the products 100 within the magazines 32, 42 and to move the products into a carton 6 located at the product input plane CC. As mentioned above, the magazines 32,42 could include vacuum suction means. In this way, the magazines 32,42 can receive, collate and load any shape or sized product 100 within the magazine 32,42 and cartons 6. The movement of the magazines 32, 42, gripping plates and pusher plates being by way of the robots 30,40 and/or remote control by a user or preprogrammed computer or numerical control.

[0059] In one embodiment a means (not shown) to fold the cartons 6 is included. This could be by vacuum, pneumatic cylinders and/or servo control motors. The cartons 6 could for example include RSC cartons, trays, crash-lock cartons or the like. The products could be for example potato chips, cereals, consumer products, or the like.

[0060] Turning to the specific drawings, Figures 1 to 3, there is shown an embodiment of the present invention with both robots 30,40. The first robot 30 being ready to load the first magazine 32 into the carton 6 located on the product input plane CC. In this embodiment the two magazines 32,42 are in alignment above and below each other. The second robot 40 being ready to load product 100 into the second magazine 42. Figures 4 to 7 show robots 30, 40 in a first position. Figures 8 to 11 show robot 30 in a second position loading product 100 into the magazine 32. Figures 12 to 15 show robot 30 in another position loading product 100 into the magazine 32 from a different angle.

[0061] During use, product 100 enters the frame 2 via the product conveyor 3 in a preferred form angled to the horizontal (axis XX). Positioned at the end on the conveyor 3 are two . loading magazines 32,42, each attached to a six or seven axis robot arm 30,40. Assuming the first robot 30 starts the sequence of operation; the loading magazine 32 is tilted at an angle to both the XX and YY axis. The angle provides positive product placement in the magazine 32 without the possibility of it moving during loading. The loading magazine 32 is indexed by variable increments to suit individual product requirements. The loading magazine 32 incorporates motor or pneumatic driven side plates used to grip and support the collated product 100 during transfer to the awaiting carton 6. It also incorporates a pusher plate at the PCT/AU2013/001330 WO 2014/075151 9 base to positively insert product 100 into the carton 6. Typically, in use the magazine 32, 42 will be op'en larger than the carton 6 size during collation. During transfer to the empty carton 6 the sides will contract to be smaller or similar to the internal carton size. The magazine 32, 42 is partially loaded into the empty carton 6 and the base used to push product into the carton 6. This enables tight fitting products 100 to be packed. The two robots 30,40 are positioned to allow seamless transfer of product 100 into the magazines 32,42. That is, in the preferred embodiment the robots 30, 40 follow each other in a vertically downward direction after filling with product 100. After off-loading product 100 the robots 30,40 move horizontally away from the product input plane CC before moving vertically upwardly to receive new product from the product conveyor 3. The robots 30,40 continue in this loop. The second robot 40 is offset and elevated to allow the robots 30, 40 to share the confined workspace. As robot 30 moves down at an angle product 100 is positioned in the loading magazine 32. With the last product 100 loaded into the magazine 32 of robot 30, the magazine 42 of robot 40 takes over to collate product 100 in the same manner. Product 100 can be collated across either the narrow or wide edge of the magazine 32,42 to accommodate final packaging orientation requirements. During the above operation a fully formed carton 6 is presented to the frame 6 in the horizontal plane XX. When in position the carton 6 is tilted into the frame 2 for loading with its loading opening at an angle to axis a to the vertical axis YY. The loading position can be to the front or rear of the frame 2. In the drawings only front loading is shown. With a carton 6 in position, robot 30 moves to load collated product 100 into the awaiting angled carton 6. When loaded the carton 6 rotates to the horizontal plane XX and is transferred back onto the conveyor 4 or another conveyor (not shown). The tilting member 20 calls for a new empty carton 6 ready for presentation to robot 40. The tilting member 20 could be a conveyor in its own right. When loaded, robot 30 positions its loading magazine 32 above robot 40. When the magazine 42 of robot 40 is full it moves to load collated product 100 into an awaiting angled carton 6.

The above sequence is repeated to provide seamless product transfer without the need to adjust belt speeds to accommodate product accumulation.

[0062] Further embodiments of the invention are shown in Figures 16 to 21. For example, Figure 16 show's both robots 30,40 positioned behind the exit of the product feed conveyor 3. This provides an option for boxes 6 to travel through the cell or frame 2 perpendicular to the product conveyor 3 or through the cell 2 parallel to the product conveyor 3. The loading position also has the option for tilting the box 6 if required. PCT/AU2013/001330 WO 2014/075151 10 [0063] Figure 17 shows both robots 30,40 positioned the same as above. The boxes 6 travel through the cell 2 parallel to the product conveyor 3. The loading position can be moved anywhere along this axis to be under the exit of the product conveyor 3 or in front as per the drawing. The loading position also has the option for tilting the box 6, if required.

[0064] Figure 18 shows a variant of Figure 17 with the box 6 being loading in the reverse in- · line orientation.

[0065] Figure 19 shows both robots 30,40 positioned in front of the product feed conveyor 3. The product feed conveyor 3 is split enabling us to feed each robot 30,40 independently. This allows each robot 30,40 to have its own work space and we are able to increase the packing speed as we no longer have the change over from one robot to the other at the pickup point.

The drawing shows the box 6 traveling perpendicular to the product in-feed 3 however we also have the option for it to travel parallel through the cell 2. The loading position also has the option for tilting the box 6 if required.

[0066] Figure 20 shows a variant of Figure 19 with a box 6 being loaded in the reverse in-line orientation using the twin conveyor in-feed system.

[0067] Figure 21 shows both robots 30,40 positioned in front of the product feed conveyor with a single product conveyor. The drawing shows the box 6 traveling perpendicular to the product in-feed however we also have the option for it to travel parallel through the cell 2. The loading position also has the option for tilting the box 6 if required.

[0068] In an embodiment a 12,13,14 or 15 axes robot could be utilised in the cell or frame.

[0069] Advantageously, in a preferred embodiment the collation comes in one direction and there is “reverse flow packing” once collated.

[0070] The present invention, at least in a preferred embodiment, also provides a small packing assembly 1 with flexibility to handle all types of packing. Advantageously, the present invention, at least in a preferred embodiment, provides a highly flexible single assembly to handle case/tray erection, horizontal and vertical packing without limited product accumulation. The assembly provides a small footprint to a maximum width of about 2 metres. PCT/AU2013/001330 WO 2014/075151 11

The assembly will also accommodate customers changing requirements as it is easily adaptable. The assembly is suitable for any typical packaged or non-packaged product that can be picked up by a robot and placed in a carton and can be operated manually or computer or numerical control and include one or more control housings or panels 20 or the like. The conveyors 3, 4 can also include various guides 202 or the like.

[0071] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Claims

1. A packaging assembly having: a frame operatively associated with a first conveyor and a second conveyor, said first conveyor being adapted to deliver products to said assembly and defining a product loading plane, said second conveyor being adapted to deliver cartons to said assembly and defining a carton loading plane, said cartons having a base and side walls extending upwardly from said base to an open end spaced from said base and adapted to receive said products in use; a tilt member operatively associated with said carton conveyor, said tilt member adapted to receive a said carton at a predetermined location along said carton conveyor, and move said carton from the carton loading plane to a product input plane, a first arm having a first loading magazine to receive in use product from said product conveyor; a second arm having a second loading magazine to receive in use product from said product conveyor; said first and second arms being spaced apart to permit simultaneous operation of said arms; said arms being operatively associated with each other, to permit consecutive loading of product into said respective magazines and to deliver said magazines consecutively to said opening of respective said cartons located consecutively at said product input plane.

2. A packaging assembly according to claim 1, wherein said product input plane is located at an acute angle to a vertical axis.

3. A packaging assembly according to claim 1, wherein one of said product loading plane and carton loading plane is located in a substantially horizontal plane.

4. A packaging assembly according to claim 1, wherein one of said product loading plane and carton loading plane is located at an acute angle to a horizontal plane.

5. A packaging assembly according to claim 1, wherein said product conveyor is located substantially parallel to said carton conveyor.

6. A packaging assembly according to claim 1, wherein said product conveyor is located substantially perpendicular to said carton conveyor.

7. A packaging assembly according to claim 1, wherein said conveyors are adapted to move in both directions along their respective planes.

8. A packaging assembly according to claim 1, wherein said first and second arms are six or more axis robots.

9. A packaging assembly according to claim 8, wherein said robots are mounted to said frame.

10. A packaging assembly according to claim 8, wherein said robots are spaced apart along both a horizontal and vertical axes to permit in use simultaneous operation.

11. A packaging assembly according to claim 1, wherein each said opening of each said carton includes one or more flaps, the assembly including means to apply an adhesive to said one or more flaps to seal said carton.

12. A packaging assembly according to claim 1, wherein said tilt member is mounted to said frame.

13. A packaging assembly according to claim 1, wherein said tilt member is pivotally attached to said frame.

14. A packaging assembly according to claim 1, wherein said tilt member includes an elongate bar extending from a tilt member mount across said carton conveyor, said bar in use being movable from the carton loading plane to the product input plane, and adapted to tilt the opening of a said carton to present said opening to said magazines to receive said product, said bar returning said carton to said carton loading plane once said carton has been loaded with said products.

15. A packaging assembly according to claim 14, including actuation means to move said bar.

16. A packaging assembly according to claim 15, including a sensor to activate said actuation means when a carton is located at the predetermined location.

17. A packaging assembly according to claim 1, wherein said tilt member includes a conveyor adapted in use to be moved to the product input plane.

18. A packaging assembly according to claim 1, wherein each said loading magazine includes a pair of gripping plates separated by a pusher plate, and actuation means, the actuation means being adapted to move said gripping plates towards and away from each other and to move said pusher plate in a perpendicular direction to said gripping plates in use, to permit positioning of said products within said magazine and to move said products from said magazine into a said carton.

19. A packaging assembly according to claim 18, wherein each said loading magazine includes suction means.

20. A packaging assembly according to claim 15 or 18, wherein said actuation means includes one or more motors.