EP1927544B1

EP1927544B1 - Machine for unpacking, replacing and repacking items packed in boxes

Info

Publication number: EP1927544B1
Application number: EP07121680A
Authority: EP
Inventors: Giovanni Battista Casaglia
Original assignee: BRESCIANI MARIA; Casaglia Federico; Casaglia Silvia; CIT Srl
Current assignee: Cit Srl En Bresciani Maria En Casaglia Federi
Priority date: 2006-11-30
Filing date: 2007-11-27
Publication date: 2009-08-19
Anticipated expiration: 2027-11-27
Also published as: ITMI20062307A1; ATE440030T1; EP1927544A1; DE602007002037D1; ES2331928T3

Abstract

There is described a machine for unpacking, replacing and repacking items packed in boxes, preferably a package leaflet, comprising feeding means (5,9) for the items packed in closed boxes (3), at least one box opening station (100), at least one picking station (200) for the item (1) to be replaced, at least one inserting station (300) for an item (7) replacing said replaced item (1), at least one closing station (400) for the box (3) containing the replaced item (7).

Description

The present invention relates to a machine and a method for unpacking, replacing and repacking items packed in boxes.
Packed item means any element contained in a small-sized closed box, such as for example the package leaflets related to pharmaceutical products, or the pharmaceutical products themselves.
Several component elements may be contained in a closed box, all potentially to be replaced.
Small-sized box means, for example, a box containing pharmaceutical products.
Precisely in the pharmaceutical field, the need to replace the package leaflet contained in a previously closed box may arise. The pharmaceutical product contained therein may not have expired and it is thus sufficient to replace the package leaflet only.
Said replacement operation is currently performed by hand by a dedicated operator.
This implies a considerable waste of time with consequent increase of costs.
The need to replace one or more packed items may arise also in food field, cosmetic field or in any other case in which packed items are present.
It is the object of the present invention to make a machine capable of opening a closed box, replacing an item contained therein and closing the box itself, specifically said item possibly being a package leaflet related to a pharmaceutical product.
According to the invention, such an object is achieved by a machine for unpacking, replacing and repacking items packed in boxes, preferably package leaflets,
characterized in that it comprises
feeding means for items packed in closed boxes,
at least one box opening station,
at least one picking station for the item to be replaced,
at least one inserting station for an item replacing said item to be replaced,
at least one closing station for the box containing the replaced item.
The invention also relates to a method using the machine, as defined in claim 15.
These and other features of the present invention will be further explained in the following detailed description of an embodiment thereof shown by way of non-limitative example in the accompanying drawings, in which:

figure 1 shows a partially diagrammatic top plan view of a machine according to the present invention;
figure 2 shows an enlarged portion of figure 1 in a first box loading configuration;
figure 3 shows the same portion as figure 2 in a subsequent configuration to figure 2;
figure 4 shows the same portion as figure 2 in a subsequent configuration to figure 3;
figure 5 shows a right-hand view of figure 1;
figure 6 shows a partially sectioned, bottom view of figure 1 of the opening station in a first configuration;
figure 7 shows a similar view to figure 6 in a second subsequent configuration to that of figure 6;
figure 8 shows a similar view to figure 7 in a second subsequent configuration to that of figure 7;
figure 9 shows a side view with enlargement of a box opening step;
figure 10 shows a partially sectioned, bottom view of figure 1 of the picking station in a first configuration;
figure 11 shows a similar view to figure 10 in a second subsequent configuration to that of figure 10;
figure 12 shows a similar view to figure 11 in a second subsequent configuration to that of figure 11;
figure 13 shows a section view taken along line XIII-XIII in figure 10;
figure 14 shows a section view similar to that of figure 13 in a subsequent configuration to figure 13;
figure 15 shows a section view similar to that of figure 13 in a subsequent configuration to figure 14;
figure 16 shows a section view similar to that of figure 13 in a subsequent configuration to figure 15;
figure 17 shows a bottom view of figure 1 of the inserting station;
figure 18 shows a section view taken along line XVIII-XVIII in figure 17;
figure 19 shows a section view similar to that of figure 18 in a subsequent configuration to figure 18;
figure 20 shows a section view similar to that of figure 18 in a subsequent configuration to figure 19;
figure 21 shows a section view similar to that of figure 18 in a subsequent configuration to figure 20;
figure 22 shows a section view similar to that of figure 18 in a subsequent configuration to figure 21;
figure 23 shows a top view of figure 1, i.e. a frontal view of the closing station;
figure 24 shows a top plan view of a portion of the closing station;
figure 25 shows a top plan view of a further portion of the closing station;
figure 26 shows a vertical section view of a first closing configuration;
figure 27 shows a vertical section view similar to that of figure 26 in a subsequent configuration to figure 26;
figure 28 shows a vertical section view similar to that of figure 26 in a subsequent configuration to figure 27;
figure 29 shows a vertical section view similar to that of figure 26 in a subsequent configuration to figure 28;
figure 30 shows a vertical section view of a further closing of the box;
figure 31 shows a vertical section view similar to that of figure 30 in a subsequent configuration to figure 31;
figure 32 shows a partial frontal view of the closing station in a first configuration;
figure 33 shows a similar view to that of figure 32 in a subsequent configuration;
figure 34 shows a similar view to that of figure 33 in a subsequent configuration;
figure 35 shows as partial front view from the bottom of figure 1;
figure 36 shows a perspective view of a box with seal;
figure 37 shows a side view of a box with seal.

A machine for replacing a package leaflet 1 contained along with a pharmaceutical product 2 in a closed box 3 (packed item) comprises a base frame 4 which supports two parallel rows of step-by-step advancement pushers 5 (figure 5) of the box 3.
The advancement step is managed by a control unit 150. The advancement may also be of continuous type with programmed stops instead of step-by-step type as in the present embodiment.
Furthermore, said machine comprises, within a protective Plexiglass enclosure 160, an opening station 100 of the upper flap 16 of the closed box 3, a picking station 200 of the package leaflet 1, an inserting station 300 of a new package leaflet 7 and a closing station 400 of the box 3 containing the new package leaflet 7.
Figure 1 shows a partially diagrammatic plan view of the machine as a whole. Said stations 100, 200, 300 and 400 will be described in detail with reference to the subsequent figures.
Said closed box 3 (packed item) is positioned (figures 2-4) on the machine by an arm 8 rotationally movable between a gripping position of the box 3 placed on a loader 9 with minimum load sensor 70, box presence sensor 71, and an unloading position of the box 3 between two pairs of pushers 5 (figure 5).
Said gripping is performed by one or more suction cups 10, placed at the end of the arm 8, driven by a pneumatic vacuum generating system.
The picking may also occur mechanically, without any suction cup (whatever gripping means).
A sensor 72 integral with the frame 4 detects the positioning of the box 3 on the machine.
The correct positioning of the box 3 is aided by a horizontal bar 12, parallel to the step-by-step advancement direction of the box 3, ending with a joined portion 73 essentially orthogonal to the bar 12. Said bar 12 is selectively and horizontally movable between a rest position and a working position (figure 3) in which it aids the positioning of the box 3.
Said bar 12 is supported by a horizontal guide 112 of the box 3.
A cutting station 99, upstream of the opening station 100, comprises an adjustable cutting blade 98 for cutting a seal 97 or a label 96 of the box 3.
The station 100 comprises a body 13 selectively and vertically movable between a raised rest position and a lowered working position in which a plate 14 with hooked end 15 hooks up the upper flap 16 of the box 3 to be opened.
A pneumatically driven suction cup 130 provides for facilitating the entrance of the hooked end 15 in a compartment 23 of the box 3 to be opened (figure 9).
A horizontal fixed plate 17 with pointed end 18 favours the opening of the upper flap 16 partially raised by said plate 14.
A sensor 19 detects the opening of the upper flap 16.
The station 200 (figures 10-16) comprises a vacuum suction tube 20 integral with a plate 21 selectively movable along guides 22, by means of sliding bars 180, between a raised rest position and a lowered working position in which the end of the tube 20 comes into contact with the folding zone of the package leaflet 1. The vacuum suction determines the coupling of the package leaflet 1 which is then removed from the compartment 23 of the box 3 following the raising of the tube 20.
A sensor 24 detects the picking of the leaflet 1 and means emitting compressed air by means of the mouths 25 eject the package leaflet 1 to be replaced. The same sensor 24 checks that the leaflet has been ejected. An external collector 26 (figure 1) provides for accumulating the rejected leaflets 1.
As for the picking, the leaflet 1 may also be ejected by simply mechanical means (e.g. a automated arm with movable gripping fingers).
The station 300 (figures 17-22) comprises a pair of reciprocally integral rods 31-32, selectively and vertically movable between a raised rest position and a lowered working position. The first rod 31 comprises a 'paddle' shaped end 33 adapted to push the new replacing leaflet 7, by means of a chute lead-in 34 of a horizontal plate 35, into the compartment 23 of the open box 3.
A horizontal vacuum suction tube 36 and a compressed air emitting tube 37 provide for facilitating the entrance of the new leaflet 7 in the compartment 23 of the box 3. Mechanical means may be provided to facilitate the entrance of the new leaflet.
The second rod 32 comprises a flat end 38 adapted to further push, in the next step, the new leaflet 7 into the compartment 23 (figure 22).
The leaflet 7 may also be inserted by pneumatic means or by an automated arm with movable gripping fingers.
The station 400 (figures 23-34) further comprises a feeler 47 with flat lower end 91 (figure 23), selectively and vertically movable between a raised rest position and a lowered detecting position of the presence of the item 7 (item to be repacked).
The station 400 further comprises three adjustable bars 41-43 adapted to impose a closing movement of the upper flap 16. The front upper side flap 44 (figure 32) is put into a closing position by a fixed body 45 with rounded tip (figures 32-34), while the rear upper side flap 90 is put into a closing position by a hammer 46 rotationally movable between a rest position and a pushing position for closing said rear upper side flap 90.
A similar system may be provided in the opening station 100 after lifting the upper flap 16 of the box. In fact, in case that one side flap is places upon another, it is necessary to lift said placed upon upper flap to allow the access to space into the box. A hammer 46 as above described or any other pendant mean may be functional for that object.
A first and a second horizontal rods 50-51, flat at their lower part, selectively and vertically movable between a raised rest position and a lower pushing position of the upper flap (figures 30-31) belong to the same station 400.
A belt conveyor 60 (figure 1) provides for ejecting the closed box 3 with the new package leaflet 7 inside, repacked along with the corresponding pharmaceutical product 2.
As concerns the operation of the machine, the arm 8 (figures 2-4) provides for picking the closed boxes 3 one at a time, with the leaflet 1 to be replaced and the pharmaceutical product 2 packed, from the loader 9 positioning them between two pairs of pushers 5, specifically two upper pushers and two lower pushers which move integrally. In this manner, the handling push is well distributed on the smaller side surface 80 (figure 2) of the box 3.
After the box 3 has been positioned by the arm 8 by means of the suction cups 10, the bar 12 moves horizontally towards the box 3 (figure 3). The bar 112 is fixed and supports the movable bar 12. The joined portion 73 allows a better positioning of the box 3. Then the box 3 is moved to the next step and the bar 12 returns to the initial rest position waiting for a new closed box 3 to be loaded (figure 4).
The positioning of the box 3 is such that the bar 12 and the portion 81 of the supporting frame 4 of the box act as guides for the step-by-step advancement of the box 3.
The sensor 70 provides for stopping the machine in the case of lacking of boxes 3 in the loader 9; the sensor 72 detects the presence of the box 3 and activates the control unit 150.
The closed box 3 advances step-by-step until it reaches the cutting station 99. The blade 98 is positioned (as in a common cutter) to cut the seal 97 (figure 35). In such a manner, the seal 97 remains integral with the upper flap 16 without any bond with the side surface of the box 3. The blade 98 is supported by an adjustable body according to the dimensions of the box.
There may be a label 96 to be cut in the same manner either instead of or along with (over) the seal 97.
A removal station of an adhesive label which contemplates heating means of the adhesive (also by radiation with common sources of heat, such as a laser) and subsequent mechanical removal of the label (by means of a mechanical arm or the like) may be contemplated. Chemical means (solvents, nitrogen, etc.) may also be provided to remove the adhesive label.
Having reached station 100, the closed box 3 stops: the plate 14 descends until it enters in compartment 23 through a narrow gap (where the cut was made); the hooked end 15 engages with the terminal part of the flap 16 and, following the upward movement of the body 13, said upper flap 16 is raised (figure 9).
The suction cup 130 'pulls' the front side surface 80 outwards thus favouring the entrance of the hooked end 15.
A suction cup system which is attached to the upper flap 16 and lifts it may be contemplated instead of the aforesaid plate 14.
The box 3 starts to advance again and the upper flap 16 interacts with the pointed end 18 determining the complete opening of the upper flap 16.
The box 3 has been unpacked.
The sensor 19 detects whether the upper edge 16 has been correctly opened, otherwise the machine stops and the operator must intervene.
The box 3 with the upper flap 16 fully raised, in virtue of the fixed plate 17, reaches the picking station 200 of the package leaflet 1 to be replaced (figure 10-16).
The tube 20 descends to touch the folding zone of the package leaflet 1 (normally it is folded, thus enveloping the pharmaceutical product 2 as shown in figure 13). The pneumatic suction system makes the leaflet 1 integral with the end of the tube 20 which, by raising, drags the leaflet with it (figures 13-16).
The sensor 24 detects whether the leaflet 1 to be eliminated has actually been extracted from the box 3. If the leaflet 1 is missing, the machine stops and the operator must intervene.
After the extraction from the box 3, compressed air exits from a mouth 90 adapted to disengage the leaflet 1 from the tube 20 and to make it drop into the collector 26. The same sensor 24 controls that the leaflet 1 has actually been ejected.
A simple suction cup or a mechanical gripping arm of the leaflet 1 may be contemplated instead of the tube 20 with vacuum suction system.
The box 3 opened and emptied of the package leaflet 1 to be replaced resumes its step-by-step advancement and reaches the inserting station 300 of a new package leaflet 7 (figures 17-22).
A belt feeder (not shown) of replacing package leaflets 7 places the leaflet 7 on the plate 35 over the chute 34. The leaflet 7 is unfolded on said horizontal plate 35.
The paddle 33 descends to push the leaflet 7 into the compartment 23 of the box 3 by means of the chute 34 (figure 19). The leaflet 7 is placed on the plate 35 so as to be 'hit' by the paddle 33 at the middle line and so as to fold up the leaflet 7.
The tubes 36 and 37 facilitate the entrance of the leaflet 7 into the compartment 23 (figure 18): the tube 37 pushes the pharmaceutical product 2 towards the rear wall of the box 3; the tube 36 pulls the front wall of the box 3 outwards.
A bolster of the box 3 which at the inserting station 300 is inclined outwards may further be contemplated, thus further facilitating the entrance of the new leaflet 7.
Then the box 3 resumes moving step-by-step until to be underneath the flat end 38 of the rod 32: the box 3 stops and the flat end descends to pushe the leaflet 7 further into the compartment 23 (figure 22).
The box 3 starts moving again and the upper flap 16 is disengaged from the fixed plate 17: the upper flap 16 is folded slightly forwards, the box 3 with the new package leaflet 7 however remaining essentially open.
At the closing station 400 (figures 23-34), the upper flap 16 of the box 3, moving step-by-step, interacts with the first bar 41 which induces a complete opening of the flap 16 (figure 26). The second and the third bars 42-43 which subsequently interact in sequence determine the closing of the upper flap 16.
Specifically, it is the geometry of the three bars 41-43 combined with the motion of the box 3 to induce the closing of the box 3 itself.
Before closing the upper flap 16, the feeler 47 descends to verify the presence of the item 7, the hammer 46 closes the rear upper side flap 90, and the fixed body 45 closes the front upper side flap 44 (figure 32-34).
The horizontal rods 50-51 contribute to better close the upper flap 16 downstream of the three bars 41-43 (figures 30-31).
A further station for placing a new seal 97 and/or a new label 96 may be contemplated. Said station comprises sealing and labelling means (including possible gluing means) normally marketed.
The box 3 with the new package leaflet 7 is conveyed out by means of the belt conveyor 60.
The machine according to the present invention may contemplate several opening stations 100, several picking stations 200, several inserting stations 300 and several closing stations 400.

Claims

A machine for unpacking, replacing and repacking items packed in boxes (3), preferably package leaflets:
characterised in that it comprises
feeding means (5, 9) for items packed in closed boxes (3),
at least one box (3) opening station (100),
at least one picking station (200) for the item (1) to be replaced,
at least one inserting station (300) for an item (7) replacing said item to be replaced (1),
at least one closing station (400) for the box (3) containing the replaced item (7).
A machine according to claim 1, characterised in that said opening station (100) comprises a plate (14) with a hooked end (15), selectively and vertically movable between a raised rest position and a lowered working position for lifting an upper flap (16) of the closed box (3) and a suction cup 130 for pulling a front side surface (80) outwards favouring the entrance of the hooked end (15)..
A machine according to any claim 1-2, characterised in that said opening station (100) comprises a fixed plate (17) with a pointed end (18) for lifting the upper flap (16) of the box (3) and/or pendant means (46) for lifting side flaps (44, 90) of the box.
A machine according to any claim 1-3, characterised in that said opening station (100) comprises a sensor (19) for detecting the opening of the upper flap (16) of the box (3).
A machine according to any preceding claim, characterised in that said picking station (200) comprises gripping means (20), preferably pneumatic suction cups means, selectively and vertically movable between a raised rest position and a lowered gripping position of the item (1) to be replaced.
A machine according to claim 5, characterised in that said picking station (200) comprises a sensor (24) for detecting the picking of the item (1) to be replaced and the ejection thereof.
A machine according to any claim 5-6, characterised in that said picking station (200) comprises pneumatic or mechanic ejection means (25) of the item (1) to be replaced.
A machine according to any preceding claim, characterised in that said inserting station (300) of the replacing item (7) comprises a horizontal plate (35) with downward chute opening (34) for the passage of the replacing item (7) and a couple of reciprocally integral inserting and pushing means (31-33, 35, 38) selectively and vertically movable between a raised rest position and a lowered position wherein the replacing item (7) is placed inside the open box (3).
A machine according to claim 8, characterised in that it comprises pneumatic suction means (36), preferably suction cup means, adapted to temporarily widen the compartment (23) of the box (3).
A machine according to claim 9, characterised in that it comprises means (37) for emitting air to appropriately place a possible second product present in the compartment (23) of the box (3).
A machine according to any of claims 9-10, characterized in that it comprises a bolster inclined outwards for facilitating the entrance of the new leaflet.
A machine according to any of the preceding claims, characterised in that said closing station (400) comprises three adjustable bars (41-43) the geometry of which is adapted, in combination with the motion of the box itself (3) imposed by the handling means (5), to impose a closing movement on the upper flap (16) of the box (3).
A machine according to any preceding claim, characterised in that it comprises a removing station (99) of a seal (97) and/or a removing station (99) of a label (96).
A machine according to claim 13, characterised in that said station (99) comprises cutting means, preferably a blade (98), adapted to cut said seal (97) and/or said label (96).
An unpacking, replacing and repacking method of a packed item (1), preferably a package leaflet, by a machine according to any of the preceding claims, characterised in that it comprises the steps of:
- opening the closed box by lifting the upper flap of the initially closed box (3);

- picking an item (1) to be replaced;

- inserting a replacing item (7);

- closing the box (3) with the new item (7).
A method according to claim 15, characterised in that it comprises the removal of a seal (97) and/or a label (96).
A method according to claim 16, characterised in that it comprises the cutting of the seal (97) and/or a label (96).