BE1030730B1 - Manipulation device for folding products and associated methods - Google Patents

Abstract

Manipulation device for folding products comprising an entrance; and an exit; wherein the manipulation device defines a product path between the entrance and the exit; wherein the manipulation device further comprises: a transport device configured for moving a product along the product path; a first gas manipulator connected to the product path, wherein a nozzle of the first gas manipulator is configured to deliver pressurized gas in a first orientation relative to the product path for manipulating a product on the conveyor device; a second gas manipulator connected to the product path, wherein a nozzle of the second gas manipulator is configured to deliver pressurized gas in a second orientation relative to the product path for manipulating the product on the conveyor device, the second orientation being different is of the first orientation.

Description

1 BE2022/5602

Manipulation device for folding products and associated methods

AREA

The present invention relates to a device and associated methods for folding a product, in particular a secondary packaging, for example for consumer goods with a high turnover rate, such as drinks in cans and bottles.

BACKGROUND

The production, assembly and distribution of many products requires high-capacity folding of part of a product relative to the rest of the product. An example of this is setting up and closing packages.

Large-scale production is characterized by the high-capacity packaging of objects or goods of various shapes and sizes, these objects usually being purchased in groups and packed as such in bundles, cases, crates, baskets, boxes, totes, bags and the like ( where the objects are usually grouped according to the same or similar size, shape, color, material types, weight, etc.). The demands placed on manufacturing processes, especially in the area of high-velocity consumer goods (FMCG), are characterized by long reach, high capacity and efficient changeover, to name just a few.

Conventional large capacity machines can currently typically provide high output, but only for a limited number of object configurations, e.g. objects of a certain size or shape, and where these objects can only be grouped into a small number of predefined grouping quantities. Conventional packaging assembly lines therefore usually require extensive use of spare parts to package different sizes and/or configurations (patterns and quantities) of objects. This ultimately impacts capital equipment and operating costs, the amount of transportation required, the amount of real estate in the factory, the workforce, utility consumption and productivity, etc.

2 BE2022/5602

Traditionally, packaging manipulation is done by mechanical means, for example using rotary pleaters, pushers, mandrel and mold (cavity) plunge forming tools, folding rails, flap folding arms and/or plows to close or close foldable and/or wrap-around packaging flaps (panels). otherwise manipulate.

These mechanical means often require long conveyor belts to close the flaps, which takes time and, crucially, requires some length of the machine and thus takes up a lot of space in the factory.

A second disadvantage of using mechanical means to manipulate packages is that the collision between the package and the manipulation element (e.g. an arm), which is necessary to manipulate the package, entails the risk that the package or whatever is inside it is damaged.

Importantly, in all production lines, the speed of a product, such as secondary packaging, along a production line is linked to the time required to manipulate the product (e.g. packaging) into a desired configuration, the length of the machine and /or production line dictates. The length of the production line determines the factory space required to install the production line, with larger factory spaces being more expensive. It is therefore desirable that foldable products such as packaging are assembled in the shortest possible time, ultimately resulting in the shortest possible production line, thus minimizing the necessary space and factory costs.

RESUME

The present disclosure provides a device and method for manipulating products, in particular products that can be folded (i.e. a “foldable product”) - such as secondary packaging (e.g. cardboard packaging) - with a high capacity and requiring as short a possible distance (and therefore machine length) without having to exchange components.

The present disclosure relates to a manipulation device for use with any foldable and/or wrap-around product. A particularly relevant example of such products is packaging, in particular secondary packaging. Other examples of products include toys, marketing materials, or point-of-sale displays. References in this document to “packaging”, “packaging product” or “secondary packaging” are also applicable

3 BE2022/5602 applies to other foldable and/or wrap-around products unless expressly stated otherwise.

The present disclosure further provides a device and method for manipulating packages; avoiding the use of mechanical manipulation means that come into contact with the packaging during assembly, which could affect the packaging through shear forces and which could entail a real risk of damage to the packaging. The manipulation of the packaging is carried out using pressurized gas.

Since the invention of the present disclosure does not use mechanical components adapted to and in contact with a package to manipulate it into a desired assembly state, the production line has a greater degree of flexibility; where the main advantage is that the need to change components is eliminated. For example, the components on the production line that perform the required manipulations can be easily and quickly moved, reoriented and/or reconfigured for packages of new dimensions introduced on the production line. The elimination of the need for spare parts thus significantly increases the range of different types of packaging that can be manipulated, significantly reduces the downtime required to change machine setups between different production runs and significantly reduces the space required (e.g. for the storage of spare parts).

The reorientation and/or reconfiguration of the components on the production line that perform the different manipulations can be automated and directed to predetermined packaging-specific configurations according to a menu item selected via the control panel (HMI). Optimized performance of any setup and/or its operation can be achieved through artificial intelligence, further increasing the efficiency, precision and performance of the device. This also offers a safer facility, as no human contact is required when reconfiguring the production line components through the substitution of spare parts for other packaging configurations and contact with the product and moving mechanical mechanisms are avoided in favor of contactless (mechanical) devices without moving components.

4 BE2022/5602

In particular, when using gas manipulators as the components on the production line to manipulate packaging, much faster manipulation could be observed. Faster manipulation of the packaging allows a higher throughput of the machine, as more operations can be performed within a given period. It also reduces the overall size of a packaging line, as the same manipulation can be performed within a shorter distance when a package moves through a production process. This allows for more compact packaging lines, requiring less floor space and factory space to house the production line(s), reducing real estate costs.

Manipulating a product using devices according to the disclosure prevents manipulator components from penetrating any path on which a package is moved from an entrance to an exit; thus reducing the risk of damage to the packaging or an operator.

One aspect of the present disclosure relates to a manipulation device. The device includes an entrance; and an exit; wherein the manipulation device defines a product path between the entrance and the exit; wherein the manipulation device further comprises: a conveying device (e.g., a conveyor belt or a mover) configured to accurately move a product along the product path; where the product trajectory defines a machine direction along which the product moves from the entrance to the exit. The device further includes a gas manipulator positioned around the production path and configured to deliver pressurized gas for manipulating the packaging product on the conveyor device.

A manipulation device for folding products comprising: an entrance; and an exit. The manipulation device defines a product path between the entrance and the exit. The manipulation device further includes: a conveying device (e.g., a conveyor belt, mechanism, or independent mover) configured to move a product along the product path. The manipulation device also includes a first gas manipulator connected to the product path, configured to deliver pressurized gas in a first orientation relative to the product path for manipulating a product (e.g., while stationary or in motion is between the entrance and the exit) on the transport device. The manipulation

device also includes a second gas manipulator connected to the product path, configured to deliver pressurized gas in a second orientation relative to the product path for manipulating the product (e.g. while stationary or in motion between the entrance and the exit) on the transport device, wherein the second orientation is different from the first orientation.

A package may be any container, carton, crate, box, envelope, bag, cover or other container or means of holding together or maintaining in position, derived from the folding and/or winding of a sheet-type material in a two- or three-dimensional shape.

The manipulation device according to the disclosure can be configured to receive products - e.g. packages - in an unfolded condition and deliver products in a folded condition. The handling device may be a stand-alone device or may be part of a larger production line, in which the device may receive products from a preceding device such as a product packaging device, and deliver products to a subsequent device, such as a stacking device. products or a transport device.

The manipulation device provided in this way allows products on the product path to be manipulated in a desired, predefined intermediate or final configuration. For example, a package can initially be provided flat and unfolded (i.e. as a blank) at the entrance to the route. Said blank can then be folded by gas manipulation into a folded or erected configuration into which items or goods are or could be inserted therein.

Alternatively, a partially folded package can be provided at the entrance of the route, with the remaining unfolded parts being folded by gas manipulation into a final package configuration, e.g. closing the package. These gas manipulations can be performed at exceptional speeds, with more uniformly applied forces via distributed non-shear pressures and much faster than previously known in the art.

When the term “folding” is used here, it can be interpreted broadly to include wrapping, bending, interlocking, holding, pressing, inserting, or twisting. Therefore, it does not just mean that a sharp edge must be formed.

6 BE2022/5602

The gas used by the gas manipulators can be any suitable gas for the required function, for example, and preferably, air, more preferably compressed air; but nitrogen, helium or the like can also be used (e.g. for special inert applications).

The means for transporting the package through the manipulation device may include an alignment means, wherein the alignment means is configured to align the package against one or more reference points relative to the manipulation device.

The alignment means may be configured to align an axis of a package with the direction of movement of the product along the product path. The alignment means may be configured to align any fold lines on the unassembled/partially assembled package perpendicular to the direction of gas delivery by the first or second gas manipulator. This ensures minimal resistance when the package is folded. Any suitable means of alignment can be used, such as fixed or dynamic (e.g. rotating) combs, guide rails, bumpers and the like.

Although the term 'fold lines' has been used in this case, it will be clear to those skilled in the art that a fold line can be a score line, a perforated line, an imaginary fold line or another precise line on which folding such as a hinge preferably takes place.

The first gas manipulator may be configured to perform an initial manipulation of a product on the conveying device (e.g., conveyor belt or independent mover through the handling device); and the second gas manipulator may be configured to perform a second manipulation of the product on the conveyor device (e.g., conveyor belt or independent mover through the manipulation device).

The product may be a packaging product comprising a first and second flap; the first manipulation may be folding the first flap and the second manipulation may be folding the second flap.

The first flap can be folded in a first direction, the second flap can be folded in a second direction, which is different from the first direction.

7 BE2022/5602

In some examples, a manipulation may be only part of the process of folding a flap. For example, a first manipulation may include starting the process of folding a flap and the second manipulation may include completing the process of folding a flap and thus also holding the previously folded flap in place.

Having first and second gas manipulators as part of the manipulation device means that multiple manipulations can be performed on a package (or other product) without having to reorient the package on the product path, or the gas manipulators around the product path. There is no mechanical movement and no inertia to overcome or recoil to absorb from any reciprocating device. Together with the high driving speed of the gas manipulation device, this significantly increases the operating speed and therefore the capacity of the manipulation process according to the disclosure compared to existing systems.

The first and second gas manipulators may be configured to manipulate a product on the conveyor device (e.g., conveyor belt or mover) while it is in motion. That is, the gas manipulators may be configured to manipulate the product as the product moves along the product path.

The manipulation device may include a gas manipulator configured to ensure that the leading and/or trailing edge of a package is flat (straight).

This ensures minimal and more consistent resistance to folding or bending and ensures reliable, accurate and precise operation.

The first gas manipulator may comprise a nozzle. The nozzle of the first gas manipulator may be configured to deliver gas under pressure (e.g. in the first orientation relative to the product path). The second gas manipulator may comprise a nozzle. The nozzle of the second gas manipulator may be configured to deliver gas under pressure (e.g. in the second orientation relative to the product path).

To direct the delivered pressurized gas to a certain orientation, the nozzle itself may be oriented with its output axis along the respective orientation.

8 BE2022/5602

The first and/or second gas manipulators may comprise a plurality of nozzles. Each gas manipulator can comprise a plurality of nozzles.

The multiple nozzles within a single gas manipulator may have different locations in relation to the product path; and/or have different orientations towards the product trajectory; and/or, may be configured to deliver gas with different characteristics defined by at least one of: the nozzle type, the output pressure; the output flow; the exit surface; and the cross-sectional shape of the exit.

The first gas manipulator may be configured to deliver pressurized gas with first timing relative to the location of the product relative to the gas manipulator. The second gas manipulator may be configured to deliver pressurized gas with second timing relative to the location of the product relative to the gas manipulator. The second timing may be different from the first timing.

The plurality of nozzles may be configured to be triggered to operate at different times and durations relative to the position of the package relative to the manipulation device (and therefore the nozzle) and relative to each other (i.e., nozzle activation sequence).

Within a nozzle array forming a gas manipulator, one or more nozzles can be used to initiate the folding of the flaps and overcome the initial resistance to bending, while another one or more nozzles can be focused on driving the motion by a large part of the folding arc, while yet another one or more nozzles can be focused on flattening and firmly holding the then folded flap in the folded position. Each nozzle or subset of nozzles constituting a gas manipulator can be independently configured in terms of type, orientation, position and operating parameters (i.e. gas pressure applied, start and duration of operation; and sequence of operation if more than one nozzle forms an array) .

A gas flow orientation can be defined relative to an x-axis, y-axis and/or a z-axis. The x-axis is parallel to the product path and can be called the machine direction. The y-axis can be perpendicular to the x-axis and in the horizontal plane of it

9 BE2022/5602 product range; the y-axis can be transverse to the machine direction. The z-axis can be perpendicular to the x- and y-axes.

The first orientation may be located in a plane parallel to the product path for folding a first flap of a product and the second orientation may be located in a plane perpendicular to the product path for folding a second flap of the product in a direction perpendicular to that of the first flap.

The first orientation can be placed in the x-z plane. The second orientation can be placed in the y-z plane.

The first gas manipulator and the second gas manipulator may be configured to generate a gas output that has different characteristics. The gas output characteristics can be defined by at least one of: the output pressure, the output flow rate; the exit area, position, number of nozzles or outlets, duration of exit and the cross-sectional shape of the exit of the gas stream.

The nozzle(s) of the first gas manipulator and the nozzle(s) of the second gas manipulator may be configured to generate a gas output with different package manipulation capabilities and characteristics. The manipulation capability and characteristics of a gas manipulator and more particularly an individual or subset of nozzles may be defined by at least one of: the proximity, orientation and/or inclination of the nozzle with respect to the foldable flap of the packaging material on the moment of activation and during the period (duration) of operation; the output pressure; the output flow rate, area and cross-sectional shape as defined by the type of nozzle, the sequence and timing of activation and the duration of activation(s) relative to the position of the package (while normally in motion) by the manipulation device design.

Package-specific flap folding performance can be achieved by changing the position, inclination and/or orientation of one or more nozzles forming a gas manipulator, as well as the characteristics, timing, duration and firing sequence of the nozzle profiles, allowing for example higher pressure (force) and/ or another cross-section of the released gas is obtained. Furthermore, the start of the gas manipulation sequence of the second gas manipulator relative to the operational sequence of the first gas manipulator may also be configured so that,

10 BE2022/5602 while the first flap folding operation is taking place, the second operation is already being started so that the second operation secures and maintains the completion of the first operation.

The or each gas manipulator may be configured to move between a first and second arrangement. A first arrangement may be associated with a first manipulation, the second arrangement may be associated with a second manipulation.

For example, the or each gas manipulator may be configured to move between different setups between product runs, to perform different actions for each run, or to perform the same action for different products (e.g., on different packages). This reconfiguration can be controlled by the controller.

The gas manipulators, or nozzles thereof, can be reconfigured. That is, the gas manipulators or nozzles can be configured to change the characteristics of the flap manipulation effect. Since the delivery of the manipulators/nozzles can be reconfigured, the device can be used with a wide variety of packages and can perform a range of different manipulations. Packaging with different heights, widths and lengths, and therefore also calibers of the packaging material (stiffness of the panel and increase in folding resistance per unit length), dimensions of foldable panels and therefore larger surface areas and breakline lengths; can be manipulated on the product path while stationary or in motion and without replacement parts.

Alternatively or additionally, different materials can be used with the device that have different resistances to manipulation, e.g. folding and/or bending.

The manipulation devices can be placed on, adjacent to, around or above the product path and/or the transport device.

The manipulation device may include reconfigurable robot arms positioned to support the gas manipulators and/or nozzles thereof. This arrangement can allow rapid reconfiguration of the gas manipulators (e.g. in preparation for manipulating a different type of product (e.g. primary product type, size (diameter & height), quantity and pattern within the package).

The manipulation device may include sliding actuators. The gas manipulators and/or nozzle(s) of the gas manipulators can be placed on sliding actuators for

11 BE2022/5602 positioning so that adjustments can be made for width (y-axis) and height (z-axis) as well as the use of motorized rotatable mountings to adjust inclinations around e.g. the x-axis.

The product material is preferably cardboard, but can generally consist of different materials and different types as far as this is clear to the skilled person, such as raw/unprocessed material, laminated material, corrugated material and the like.

The packaging material mentioned may be printed (e.g. with a brand name) and/or coated (e.g. lacquered) on one or both sides. Different resistances to manipulation e.g. folding, may be offered by products formed from different materials, and/or different qualities/constructions of the same material. By being able to configure the nozzles, and therefore the gas delivery, according to the specific packaging requirements, a wide variety of packaging products can be manipulated on the manipulator device.

The disclosure manipulation device therefore offers much more flexibility compared to previous systems and can be used with a wide range of packages.

The manipulation device may include a third gas manipulator and a fourth gas manipulator, wherein the third and fourth gas manipulators are configured to deliver pressurized gas for manipulating the product on the conveyor device (e.g., conveyor belt or independent mover).

As described above, providing additional manipulators means that additional manipulations can be performed on a package as it moves along the product path. For example, in order for the package to be manipulated into its desired condition, the package may need to be folded in a number of different directions. Three or more gas manipulators can be provided within the system to increase the number of manipulations that can be easily performed in a given time period and complete linked sequence.

The first and fourth gas manipulators may be opposed to each other and located in a plane parallel to the product path, for manipulating a first pair of opposing flaps (e.g. larger inner and outer flaps) of a package on the conveyance (e.g. conveyor belt or independent mover). The

12 BE2022/5602 second and third gas manipulators may be opposite each other and located in a plane perpendicular to the product path, for manipulating a second pair of opposing flaps (e.g. front and rear small flaps) of the package.

Gas manipulators arranged in the manner described herein allow rapid manipulation of a package. Multiple manipulators can provide a series of rapid succession of manipulations, significantly reducing the time to assemble a package and/or complete a package manipulation. Gas manipulators can be used alone or in combination with conventional mechanical folding devices such as mounting rails and/or constantly rotating folders for transverse operations relative to the direction of travel by the manipulation device.

If a plurality of gas manipulators are provided, they can be arranged successively along the product path, for example so that a product passes successively past the manipulators. Alternatively, the manipulators can be located at a same point along the product path, for example so that the product passes the manipulators at the same time (i.e. the series of gas manipulators can be nested or occupy approximately the same space, resulting in a very short machine length to perform full folding operations ).

The device may be configured to sequentially operate gas manipulators for sequentially performing manipulations on the product on the conveyor device (e.g. conveyor belt of an independent mover), for example sequentially folding corresponding flaps of a package, as the product moves from the entrance goes to the exit. As described above, the device may be configured to allow the gas manipulators to quickly manipulate a package. In addition, the manipulators can be configured to operate sequentially based on the package to be manipulated. For example, different types of packaging may require different sequences of manipulations to fold multiple flaps into different flap orders to achieve a desired state.

In addition, the package handling device may be configured so that an adjacent gas manipulator begins operating before the completion of the operation by another previously activated manipulator. When a consecutive further

13 BE2022/5602 operation starts before a previously started operation is completed, the next operation can catch and hold the previous operations and can reduce the time and therefore the distance required for the machine to manipulate a product, allowing for more compact and affordable machines become possible.

The release of pressurized gas can be controlled by a valve. The valve can be a solenoid valve. Each gas manipulator can contain a valve. Alternatively, each nozzle may contain a valve. The valves are usually mounted close to or proximately coupled to the nozzle(s) and are characterized as high capacity, fast acting (opening and closing) on/off valves for precise application, maintenance and termination of delivered air pressure for realizing the precise, individual part of the flap manipulation effect and in an extremely predictable and repeatable manner.

Each gas manipulator and/or nozzle can be supplied via a local compressed air reservoir. The reservoir may be operated by a dedicated or regional or central compressed air pressure regulator that can adjust (control) the application pressure of the compressed air nozzle as part of the handling device arrangement per package to be processed. The pressure controllers are preferably digital so that the configuration per package is included in and therefore managed by the controller that sets and operates the manipulation device. The capacity of the reservoir (compressed air receiver) must ensure that there are no pressure drops in the line, and therefore no sudden and excessive pressure drops when the nozzle(s) are activated.

The gas manipulators can deliver gas between 1 and 8 bar. A gas handling nozzle or gas manipulator can be used to hold (or open) one or more flaps while another one or more flaps are being folded or a production operation is being performed. The use of different types of gas jet nozzles can be considered, from low to high gas flow capacity and with any of many different jet pattern shapes and sizes to achieve the desired power and area focus of the gas manipulation jet. Commercially available gas nozzle cartridges include flat (comb), needle (point), round and annulus, to name a few.

Any suitable valve may be used in accordance with the present disclosure. The gas manipulators can have a solenoid valve per

14 BE2022/5602 include nozzle or row or series of nozzles. A solenoid valve can apply and terminate the supply of compressed gas to the nozzle(s) with very fast and repeatable response times. For example, each nozzle can be closely coupled to a fast-acting solenoid valve, so that each nozzle can be activated and deactivated individually, and quickly. The said solenoid valves may allow 'digital' control of the gas manipulators through the nozzles, with each nozzle being either in an 'on' state or in an 'off' state, with no intermediate position.

The use of such fast acting solenoid valves can allow very precise usage control, where the time a valve is open or closed can be defined very accurately. This allows a manipulator to exert the pressure force exerted by the gas at a very precise time and for a very precise duration to carry out a desired folding/manipulation.

Providing a multitude of nozzles on a gas manipulator allows gas to be delivered over a larger surface area of a packaging product. If a flap is to be folded, it is desirable that the force applied to the flap is uniform across its surface. This prevents excessive twisting or distortion of the flap, which can cause uneven folding. Furthermore, multiple nozzles can provide greater manipulation force than one nozzle alone. For example, if a package is made of a material that has high tamper resistance, multiple nozzles may be required to provide the manipulation force to manipulate the package. Alternatively, the flow rate or volume of gas emitted through a nozzle can be adjusted to change the manipulation force. Conversely, a packaging material of limited thickness that exhibits lower bending stiffness may respond better to a more evenly distributed and mild force (low pressure) so that more uniform and even manipulation occurs without relying on the carton stiffness to withstand pressure differences.

The gas manipulator of the manipulation device may be configured to apply gas pressure evenly over the surface of a flap. This can be achieved by calibrating the number of nozzles in a gas manipulator, as well as the locations, alignments, orientations and application profiles of the nozzles. As described above, applying pressure evenly across the surface of a flap being manipulated prevents twisting and deformation of the flap being folded.

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Excessive twisting or deformation can generate erroneous results which is not desirable when fast and consistent packaging processing is required.

The first gas manipulator may be placed at a first position within the manipulation device. The second gas manipulator may be placed at a second position within the manipulation device. The multitude of gas manipulators, each with their nozzle arrangement, can be configured to activate at different activation times. In some examples, each individual nozzle of a plurality of nozzles within a particular gas manipulator may be configured to activate at a different time than the activation of an adjacent nozzle in the same gas manipulator. Cascading operation of individual gas nozzles within a single gas manipulator can provide reliable and smooth movement of a part of a product (e.g. a flap of a package) throughout its full range of motion.

Varying the positions of the gas manipulator in any of the above ways allows packages with different sizes, foldable panel (flap) shapes, materials and/or thicknesses to be manipulated by the device in a very flexible and rapid manner. For example, when a new packaging format needs to be manipulated, the adaptability of the gas manipulator(s) allows adequate reorientation, re-inclination and re-distribution of the packaging path and the new packaging itself. Adequate reorientation, re-inclination and re-spreading can be achieved by varying the inclination of a gas manipulator by changing its position along one or more of the x-axis, y-axis and/or z-axis. Additionally, varying the positions of individual nozzles within a single gas manipulator allows more controlled manipulation of a package as it moves along the product path. As described above, it is an advantage over existing production lines that use mechanical components to manipulate the packaging into a predefined state.

The manipulation device may include a compression belt positioned (e.g.: above the product path) to hold one or more flaps of a package in place on the conveying means (e.g. conveyor mechanism, conveyor belt or independent mover) after its manipulation. By using a compression strap after manipulation of a package, the package can be maintained in its manipulated condition while it is being transported.

16 BE2022/5602 advanced to the exit of the product path. For example, when packaging components are manipulated to be glued together after being folded together, a compression band can be used to ensure that the manipulated condition is maintained for a period of time until the glue has hardened.

The manipulation device may comprise a controller for controlling the operation of the first and second gas manipulators. The controller may be configured to control the operation of the nozzle(s) in the respective gas manipulators.

The controller can be any suitable controller for controlling one or more functions of the manipulation device.

The manipulation device may comprise a plurality of gas manipulators. The controller may be configured to control the automated changeover and adjustment of the manipulation device from one package format to another. The controller may be configured to regulate gas pressures per gas manipulator, row of nozzles and/or individual nozzles forming them; the automated positioning, inclination and orientation of gas manipulators and individual and/or series of nozzles forming the gas manipulators and the operation of all gas manipulators. The controller may be configured to operate the gas manipulators - e.g. by operating the nozzles or valves - to emit pressurized gas. System settings, applied gas pressures, nozzle positions and activation sequences per package format, are developed and stored in the controller for recall and reuse each time the package format is produced.

The setting and sequence can be further adjusted during a production run via the control interface with the controller and either saved as a configuration update, as a new recipe or discarded. With appropriate machine vision feedback and an adaptive machine learning algorithm, the sequences and parameters applied by the controller can be gradually adjusted to optimize performance, compensating for variations in temperature, humidity and packaging material.

The controller can be used to activate various gas manipulators/nozzles to match the progress of the packaging along the production line. This means that the sequential folding/manipulation of a package can be fine-tuned for specific manipulations that require

17 BE2022/5602 are carried out at specific points on the production line, depending on the packaging style and/or user requirements.

The controller can be programmed to operate valves associated with nozzles of any gas manipulator. The use of fast-acting solenoid valves in combination with the fact that the said valves can be controlled by a programmable controller allows the production line to be accurately 'tuned' and the pressure to be accurately controlled so that precise manipulations of the packaging can be carried out.

The controller may also be programmed to reconfigure the multitude of gas manipulators. The controller may be configured to adjust the locations, inclinations and/or orientations of (some or all) gas manipulators within the manipulation device - for example, to reconfigure the device to be used with a different package type, size, material and/or thickness. The controller may be configured to adjust the location, inclination and/or orientation of the nozzles within gas manipulators. The controller may be configured to adjust the characteristics, supply pressures, operating times, durations and activation/deactivation sequences of the nozzles.

The controller may be programmed to change the position of one or more gas manipulators and/or individual or subgroup of nozzles along and/or about one or more of the x-axis, y-axis or z-axis as defined with respect to of the product process.

The controller may include a memory storage. Said memory storage can store data in the form of preselections. The mentioned preselections include specific configurations for the positioning, gas pressure supply and operation of the gas manipulators and/or individual or sub-arrays of nozzles. The controller may optionally include operating instructions for assembling the package with specific preset/preconfigured dimensions. The controller may be able to switch between different pre-selections when the packaging at the entrance to the production line/product path is changed.

The manipulation device may include a package transport means for positively transporting the package in a predetermined manner through the manipulation device. The means of transport can be any device or mechanism

18 BE2022/5602 is known in the state of the art for the single or series-controlled linear transfer of objects. The conveyance may be a pusher, screw, indexing mechanism, conveyor, floating, or rail-mounted independent mover (i.e., linear drive). The use of an independent cart mover (linear drive) or floating mover allows the product to be moved along the product path independently of another product.

The manipulation device can be used for packaging beverage containers. It may be a device for manipulating liquor. The gas handling device and associated methods as described above can be used, alone and/or in combination with conventional methods, in the beverage production and packaging industry.

Further disclosed in the disclosure is a method of manipulating a package, for example using a manipulation device as described throughout.

Further according to the disclosure, a method for manipulating a product comprises: moving a product from an entrance to an exit of a manipulation device along a product path; operating a first and second gas manipulator for delivering gas under pressure for manipulating the product moving along the product path; wherein the first gas manipulator is associated with the product path, positioned in a first orientation relative to the product path; and the second gas manipulator is associated with the product path, positioned in a second orientation relative to the product path, the second orientation being different from the first orientation.

It will be clear to those skilled in the art that such a method offers the same advantages as those associated with the manipulation device.

Furthermore, it will be appreciated that any of the features that can be used in combination with the manipulation device can also be used/incorporated into the above method, if applicable.

BRIEF DESCRIPTION OF THE FIGURES

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Figure 1 illustrates a handling device used for closing packages using air folding, with a packaging product positioned at the entrance of the device.

Figure 2 shows the same device as in figure 1, showing a first step of closing the package.

Figure 3 shows the same device as in Figures 1 and 2, showing a second closing step.

Figure 4 shows the same device as in Figures 1 to 3, showing a third step of closing.

Figure 5 shows the same device as in Figures 1 to 4, showing a final closing step.

Figure 6 shows the same device as in Figures 1 to 5, showing a closed package being led to the exit of the device.

Figures 7a to 7f show a detailed view of the package closing steps undertaken by a handling device.

Figure 8 shows an example diagram of a manipulation device.

Figure 9 shows a further example diagram of a manipulation device, shown in relation to a product package.

DETAILED DESCRIPTION

The present invention relates to a manipulation device that can be used to manipulate a wide range of products.

In the present examples, the manipulation device serves for manipulating a package, for example with regard to folding the package into a desired configuration. As described above, it will be understood that when the term manipulation is used it includes, without limitation, the folding, wrapping, bending, interlocking, holding, pressing, insertion, twisting or the like of

20 BE2022/5602 may include components, parts, flaps, panels and the like of the packaging.

Furthermore, although the following examples relate to packaging, the present disclosure is not limited as such and the comments below apply equally to manipulation devices for manipulating other products.

The device can be included in an existing production line or as a stand-alone device. The device can be used alone or in combination with conventional folding methods. The device can be used to manipulate a wide variety of packages, where different packages may require different degrees of manipulation, e.g. a different number of folds and/or different forces to be manipulated to the desired condition. In some of the examples below the manipulation device is used to close the package; however, it will be clear that the device as such is not limited. In some examples, the same reference numbers will be used to refer to corresponding features in the figures.

Figure 1 shows a manipulation device 10 used to close package 80 using air folding, with a package positioned at the entrance 12 of the device. Figures 2 to 6 show the packaging product 80 of Figure 1 moving successively from entrance 12 to exit 14 through manipulation device 10, as further described below.

Figure 1 shows a partially assembled package 80 placed at the entrance 12 of a conveyor belt 40 of the manipulation device 10.

The manipulation device has an entrance 12 and an exit 14, which define a product path between them. A conveyor device in the form of a conveyor belt 40 is configured to move the product - in this case package 80 - from the entrance 12 to the exit 14 in an aligned position and with a controlled movement. The conveyor belt 40 is an example of a conveyor device configured for moving a product along the product path. Other examples of conveyor devices may include conventional mechanical transfer mechanisms or independent floating or rail-mounted linear drive movers. In the present examples, an arrow indicates the machine direction 50 of the manipulation device 10 - that is the vector along which a package 80 moves from the entrance 12 to the exit 14.

21 BE2022/5602

In this case, before being inserted into the device 10, the package 80 has been assembled to the point where it is now to be closed, with the main portion 82 of the package 80 having been formed, and closure flaps 83, 84, 86, 88 remaining to be are manipulated. According to the direction of travel, flap 84 is an inner large flap with a score line associated with the right side of the (in this example) rectangular package; flap 83 is an outer large flap with a score line associated with the left side of the package; flap 88 is a leading small flap with a score line associated with the front of the package while flap 86 is a posterior small flap with a score line associated with the rear back of the package. It will be clear that the flaps of the package are foldable panels of a material that has a certain bending stiffness. The bending stiffness of a flap is a function of its thickness and of the material, resins and coatings used in the flap's construction. The flaps, which are flexible, deform, buckle, bend, fold, and twist out of plane in response to point forces and/or non-uniformly applied pressure. It will be appreciated that package 80 can be inserted into device 10 in any assembly state according to user requirements (e.g., a completely blank package at the beginning of a carton setup). It will also be appreciated that although the package transport device 40 in this case is a conveyor belt, any suitable means for transporting a package can be used to move the package 80 in a desired machine direction 50, and in an aligned manner and with controlled motion (e.g. known constant speed). The device 10 may be configured to manipulate the package 80 in a manner required by the user. The conveyor belt 40 is configured to move the package 80 in a machine direction 50.

As the package 80 is moved by the conveyor belt 40 in the machine direction 50, it reaches the gas manipulator zone 20 of the device 10, comprising a plurality of gas manipulators 20a, 20b, 20c, 20d, which are positioned around the conveyor belt 40 with a clearance corresponding to allowing the package 80 to pass therethrough while also providing sufficient clearance to assume package status before closing and for any folding/manipulation operations to be performed. The manipulation device 10 of this example comprises five gas manipulators, four of which 20a, 20b, 20c, 20d are shown in Figure 1. It will be clear that any number of gas manipulators can be used, depending on the manipulations to be performed by the device 10.

22 BE2022/5602

Each gas manipulator 20a, 20b, 20c, 20d includes one or more nozzles 22a, 22b, 22c, 22d that deliver gas to a packaging target surface. The nozzles may be configured to deliver a gas stream, which may be a short pulse or an extended gas jet. It will be clear that the time required to drive the movement of a foldable panel (flap) through gas can be on the order of a fraction of a second and that the difference between a short pulse and an extended beam is therefore between only a fraction of a millisecond and several milliseconds can lie. However, if a holding function were to occur while a package is being transported from the handling device, the gas jet may continue for a fraction of a second, or longer depending on the production rate (packs per minute). The number, orientation and gas delivery characteristics of the nozzles can be configured to provide robust, reliable and non-damaging manipulation of the packaging product. This may, in some examples, require multiple nozzles in each gas manipulator with different sizes, positions, inclinations, orientations, and activation times and durations.

When the package 80 is moved in the machine direction 50 along the conveyor belt 40, it can be reoriented or positioned by an alignment device (not shown in Figure 1). The alignment device may be located in front of the manipulation device of the present disclosure and may serve to orient the packaging product 80 so that it is always in the same orientation by the time it reaches the gas manipulators. Since the product package 80 may have fold lines in the specific areas in which it is desirable to fold the package 80, it is advantageous that they be aligned with the gas manipulators to provide the least resistance to folding when manipulated by the gas manipulators. The alignment means can be any suitable alignment means, such as one or more guide rails or bumpers.

Figure 2 shows the point in the manipulation process where the package 80 has reached a position along the conveyor belt 40 where it can be processed by the gas manipulators.

In the present example, after reaching this stage, an initial manipulation is performed on the package 80 by a first gas manipulator 20a, the first gas manipulator emitting gas onto the first large flap 84 of the package 80,

23 BE2022/5602 for folding the first large flap 84 from a generally vertical position to a horizontal position.

The terms “first,” “second,” etc., when used in connection with the gas manipulators, are by no means limiting and are used merely for clarity in discussing this example. In other examples, other (differently positioned) gas manipulators may be referred to as the “first”, “second”, etc. gas manipulators.

Simultaneously with this action, the second gas manipulator 20b emits gas to maintain the first large flap 84 (and later, the second large and first and second small flaps) in a closed position.

Figure 3 shows the package 80 being moved further along the conveyor belt 40 than in Figure 2. This point shows a next stage of manipulation. In this phase, the third and fourth gas manipulators 20c, 20d are activated, expelling gas on the first and second small flaps 86, 88 respectively. When the third and fourth gas manipulators 20c, 20d are activated and expelling gas on the first and second small flaps 86, 88, these small flaps 86, 88 are moved from generally vertical orientations to a horizontal orientation and lie on top of the previously operated horizontal flap 84.

Figure 4 shows the package 80 in a further phase along the conveyor belt 40 than that shown in Figure 3. A gas manipulator (not shown) opposite the first gas manipulator 20a is activated to expel gas onto the second large flap 83 of the package for moving the second large flap 83 from a generally vertical orientation to a generally horizontal position, overlying the previously operated horizontal flaps 83, 88, 86, as shown, thus closing the package. The user may configure the device 10 to begin the next manipulation in a sequence of manipulations before the previous manipulation is completed. This is particularly advantageous because it takes less time to manipulate the package 80 into a desired configuration. For example, the first and second small flaps 86, 88 may begin moving toward the fully closed position before the first large flap 84 has reached the fully closed position.

Activating subsequent folding sequences before previously initiated manipulations are completed enables an assembly process in which the temporary and ultimate outcome of successive manipulations is the return and preservation of the

24 BE2022/5602 results of previous folding operations, i.e. small flaps 86 and 88 block the return of flap 84 and hold it down, while flap 83 blocks the return and keeps all previous folded horizontal flaps (84, 86, 88) down.

Furthermore, the gas manipulators 20a, 20b, 20c, 20d may be configured to cause gas to be ejected onto a surface of the respective flap. That is, the gas manipulators 20a, 20b, 20c, 20d are arranged to prevent gas from being emitted through an aperture or into the package being set up or closed, from generating or inducing opposing pressures and/or escaping gas flows, which could disrupt or otherwise adversely affect successful, repeatable folding operations.

Figure 5 shows package 80 being advanced along the machine direction 50 by the conveyor belt 40 to the compression belt 30 of the device 10. The compression belt 30 is provided with a clearance above the conveyor belt 40 so that the package 80 can pass underneath, with the compression belt 30 in contacts the top of the package 80 to ensure that it remains closed as it travels toward the exit 14 of the device 10. The speed of the compression belt 30 is configured to be synchronized with the speed of the conveyor belt 40. This ensures that no shear is created on the package 80 between the compression belt 30 and the conveyor belt 40. Since some or all of the flaps 83, 84, 86, 88 may include adhesive to hold them in the closed position, or may be taped in the closed position, the compression band 30 may provide a means for applying pressure to the package 80 to assist in the adhesive process (e.g. by helping to harden any glue/adhesive used to hold the flaps in place). The compression strap 30 can easily be provided to hold manipulated parts of the package in place while the product package 80 is moved to the exit 14 of the device 10. It will further be appreciated that the compression band 30 may be positioned at a different stage of the package processing, or may not be present at all in some devices.

Figure 6 shows the package 80 in its manipulated condition at the exit 14 of the device. As described above, in this case the manipulation device 10 is used to close the package 80 on a production line 40.

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The manipulation device 10 can be provided with a controller (not shown). The controller can be part of a centralized control system. The controller can be a computer. The controller may include a processor and data storage, and may be configured to receive and execute instructions for controlling the operation of the manipulation device. The controller may be provided as part of the device 10, and may be wired or wirelessly connected to the device 10. The controller may be configured to control the operation of the various components of the device, for example the movement of the conveyor belt. and the operation of the gas manipulator. The controller may provide a means for synchronizing one or more functions of the device 10 with others. The controller can be used to program the device to have certain user-required characteristics such as conveyor belt speed, compression belt speed, gas pressure, gas manipulator sequence, etc.

Figures 7a to 7f show a detailed view of the sequence described above with respect to Figures 1 to 6 where the manipulation device 10 is used to close a package 80. In Figure 7a all flaps 83, 84, 86 and 88 is shown in a substantially upright, unmanipulated condition. In Figures 7b-c, the first large flap 84 (a large flap which is a larger flap attached to the longer sides of the package) has been manipulated to the horizontal closed position by the gas manipulators. Figures 7c,d then show the next stage of the sequence of manipulations for the closing procedure, where the first and second small flaps 86, 88 (the small flaps are those attached to the shorter sides of the package) are folded towards the horizontal closed position and lying flat on top of the previously folded large flap 84.

Figures 7e and 7f show strips of adhesive 91 applied to flaps. Such strips of adhesive 91 may be particularly desirable when flaps are to be glued together. In this example, strips of adhesive 91 are provided on both small flaps 86 and 88, and on large flap 84. When the second large flap 83 is manipulated into its desired position, towards the previously manipulated (folded) flaps 84, 86, 88 , the strips of adhesive can ensure that the flap 84 remains stuck to the flap in its final state. As described above, the adhesive may be a glue, which requires time to harden so that the second large flap 83 is held in position as the package 80 is moved further toward the exit. To give this adhesive time to harden and/or extra

26 BE2022/5602 By applying pressure between the second large flap 83 and the strips of adhesive 91 while the glue hardens, the assembled package 80 can be passed under the compression band 30 (see Figure 1, for example).

Although the adhesive has been shown as strips applied to the outer surface of the first major flap (84), it will be apparent to one skilled in the art that adhesive is applied at any appropriate time during or before the folding sequence and to any area of the package ( 80) and can be applied in any desired manner, depending on the desired final configuration of the package (80). Applying the adhesive can be an additional step included in the packaging process. Alternatively, the package (80) may be provided with or have adhesive applied to it prior to further handling (e.g. assembly). Any suitable adhesive can be used to maintain the package or package parts in the desired condition. The said adhesive may be selected based on its open time, its curing time, its strength after curing or its commercial availability and cost.

Figure 7f shows the final phase of the closing sequence of the package 80, where the second large flap 83 is manipulated to the closed position, after which the package 80 moves to the exit of the device (not shown).

As discussed above, the gas manipulator device may be configured to avoid the emission of gas into areas of the flaps where apertures 85 may be present or into the body of the package that is closed, to avoid any lost force or any backflow of gas or pressure effects that can undermine the desired flap folding operation. Measures to avoid jets through flap apertures, reliefs or cutouts and/or around flap edges in the package may include the use of multiple nozzles and successive pulses thereof configured to strategically track the trajectory of the package and the simultaneous arc of motion of any flap that is manipulated. This may be associated with precision position, inclination and orientation adjustments of said nozzles when setting up the machine for a given package, together with fine, fast acting on/off control of when nozzles are activated, over what period of time, in what order and at what gas pressure (each or joint). It will be appreciated that for the sake of the speed of folding operations obtained, although this may be an option, in the present example, the

27 BE2022/5602 positions, inclinations and orientations of the nozzles constituting the manipulation device can be fixed at the time of adjustment for each package format (type).

As described above, the manipulation device 10 may accommodate packages 80 of different sizes or packages 80 that require different manipulation sequences to provide the user's desired product. For example, within the beverage industry, a wide variety of packaging 80 can be used to package different products. The product to be packaged can consist of glass bottles or aluminum cans. The said bottles or cans come in a variety of shapes, sizes, diameters and heights and may be placed in any formation in which the manufacturer wishes to sell them (such as 1 x 3, 2 x 2, 2 x 3, 3x 4, 4 x 6, etc.). Therefore, the manipulation device 10 can be reconfigurable to accommodate the different packaging required for each of these product groups.

Figure 8 shows a perspective view of a manipulation device and illustrates the reconfigurability of the example manipulation device. Arrows associated with each of the gas manipulators 20a, 20b, 20c, 20d, 20e indicate dimensions in which the respective manipulators can be moved to reconfigure the manipulators to accommodate different sized packaging products. Certain manipulators can be moved horizontally parallel to the product path (x-axis), across the product path (y-axis) and vertically (z-axis). Each gas manipulator also contains a plurality of nozzles 21, which are arranged in one or more groups or rows.

A further exemplary embodiment may include an array of machine frame and/or ceiling, wall, or floor mounted single to multi-arm static robots equipped with end effectors including one or more arrays of nozzles. In addition to the position, inclination and orientation adjustment in the major and orientation. Any means of linear side, telescopic actuator, and/or conventional robot with one or more arms and one or more joints can be used to perform the adjustment of the position, inclination and/or orientation of the one or more nozzles of series of nozzles forming the manipulation device.

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Figure 9 shows a further example diagram of a manipulation device, shown in relation to a package. Figure 11 shows that gas manipulators can be shifted in one direction along the product path to facilitate successive manipulations as the package moves through the machine.

The present invention has been described above by way of example only.

Modifications in detail may be made to the present invention within the scope of the claims appended hereto. Furthermore, features from one example may be combined with an alternative example unless such combination is expressly excluded.

Claims (15)

29 BE2022/5602 CONCLUSIONS A manipulation device (10) for folding products, comprising: an entrance (12); and an exit (14); wherein the manipulation device (10) defines a product path between the entrance (12) and the exit (14); wherein the manipulation device (10) further comprises: a conveyor device (40) configured to move a product (80) along the product path; a first gas manipulator (20a) connected to the product path, configured to deliver pressurized gas in a first orientation relative to the product path for manipulating a product (80) on the transport device (40); a second gas manipulator (20b) connected to the product path, configured to deliver pressurized gas in a second orientation relative to the product path for manipulating the product (80) on the conveyor device (40), the second orientation is different from the first orientation. The manipulation device (10) according to claim 1, wherein the first gas manipulator (20a) is configured to perform a first manipulation of a product (80) on the conveyor device (40); and the second gas manipulator (20c) is configured to perform a second manipulation of the product (80) on the conveyor device (40). A manipulation device (10) according to claim 2, wherein the product (80) is a packaging product comprising a first and second flap (84, 86); wherein the first manipulation is folding the first flap (84) and the second manipulation is folding the second flap (86). A manipulation device (10) according to any one of the preceding claims, wherein the first and second gas manipulators (84, 86) are configured for manipulating a product (80) on the conveyor device (40) while in transit. 30 BE2022/5602 A manipulation device (10) according to any one of the preceding claims, wherein the first gas manipulator (20a) comprises a nozzle (22a) of the first gas manipulator (20a) configured to deliver gas under pressure and the second gas manipulator (20c ) includes a nozzle (22c) of the second gas manipulator (20c) configured to deliver pressurized gas. 6. Manipulation device (10) according to any one of the preceding claims, wherein the first orientation is placed in a plane parallel to the product path for folding a first flap (84) of a product (80) and the second orientation is placed in a plane perpendicular (22c) to the product path for folding a second flap (86) of the product (80) in a direction perpendicular to that of the first flap. A manipulation device (10) according to any one of the preceding claims, wherein the first gas manipulator (20a) and the second gas manipulator (20c) are configured to deliver gas having different characteristics, the characteristics comprising at least one of: output pressure; output flow; exit surface; position, number of nozzles or outlets, duration of exit and cross-sectional area of exit. The manipulation device (10) according to any preceding claim, wherein the manipulation device (10) comprises a third gas manipulator (20d) and a fourth gas manipulator (20b), the third and fourth gas manipulators (20d, 20b) being configured to deliver pressurized gas for manipulating the product (80) on the conveyor (40). A manipulation device (10) according to claim 8, wherein the first and fourth gas manipulators (20a, 20b) are opposed to each other and in a plane parallel to the product path, for manipulating a first pair of opposing flaps (86, 88) of a package on the transport device (40); the second and third gas manipulators (20c, 20b) are opposed to each other and in a plane perpendicular to the product path, for manipulating a second pair of opposed flaps (83, 84) of the package (80). Manipulation device (10) according to any one of the preceding claims, wherein the device (10) is configured for successively operating gas manipulators (20a, 20b, 20c, 20d) for successively performing manipulations on the product on the transport device ( 40), for example it 31 BE2022/5602 successively folding corresponding flaps (83, 84, 86, 88) of a package (80) on the conveyor device (40), as the product (80) moves from the entrance (12) to the exit (14) moved. 11. Manipulation device (10) according to any preceding claim, wherein the delivery of gas under pressure is controlled by a valve, the valve being a solenoid valve. Manipulation device (10) according to any one of the preceding claims, further comprising a controller for controlling the operation of the first and second gas manipulators. Manipulation device (10) according to any one of the preceding claims, wherein the first and/or the second gas manipulator (20a, 20c) comprise a plurality of nozzles (22a, 22c). The manipulation device (10) of claim 13, wherein the plurality of nozzles (224, 22b, 22c, 22d) within a single gas manipulator (20a, 20b, 20c, 20d) have different locations relative to the product path; and/or have different orientations towards the product trajectory; and/or, are configured to deliver gas having different characteristics defined by at least one of: the nozzle type, the output pressure; the output flow; the exit surface; and the cross-sectional shape of the exit. A method for manipulating a product (80), comprising: moving a product (80) from an entrance (12) to an exit (14) of a manipulation device (10) along a product path; operating a first and a second gas manipulator (20a, 20c) for delivering gas under pressure for manipulating the product (80) moving along the product path; wherein the first gas manipulator (20a) is connected to the product path, arranged in a first orientation relative to the product path; and the second gas manipulator (20c) connected to the product path, arranged in a second orientation relative to the product path, the second orientation being different from the first orientation.