GB2461052A

GB2461052A - Carton folding machine

Info

Publication number: GB2461052A
Application number: GB0811168A
Authority: GB
Inventors: Tony Freemantle
Original assignee: T Freemantle Ltd
Current assignee: T Freemantle Ltd
Priority date: 2008-06-18
Filing date: 2008-06-18
Publication date: 2009-12-23
Also published as: GB0811168D0

Abstract

A carton processing machine having a common support frame (100) configured to support a plurality of functional carton processing units (101, 102, 103, 104). In particular, the machine comprises a feeder magazine (101) for holding and feeding preformed cartons, an erecting station (102) to receive the preformed cartons from the magazine and to fold regions of the cartons to provide erected cartons. A transfer actuator (103) transfers the preformed cartons from the magazine (101) to the erecting station (102). The magazine (101), erecting station (102) and transfer actuator (103) are all mounted on the common support frame (100) to provide a compact efficient carton processing machine to reduce the machine footprint and to optimise carton processing.

Description

CARTON PROCESSING MACHINE

The present invention relates to a carton processing machine and in particular, although not exclusively, to a carton erecting machine having a common support frame configured to support a plurality of carton processing units.

Cartons, typically formed from cardboard or a polymer material are widely used for packaging food items for subsequent distribution to shops and supermarkets.

A wide variety of automated machines have been developed and are configured specifically to package items of different shapes and sizes. Such machines include carton erecting machines configured to form a sleeve or box-like structure from a preformed flattened carton blank. Blanks are typically pre-creased ready for folding and gluing by the automated machine. Additional machines include collators adapted to collate individual items into bundles and to the package the bundle with a collective carton, box, sleeve or the like.

An example carton erecting machine is disclosed in GB 2381497 in which blanks are fed from a feeding station to a mandrel configured to fold and glue the carton which may then be conveyed to further processing units. * ,* ** * * .*

* Typically, conventional carton erecting machines have a number of processing units or *I* work stations that perform specific tasks, in series, such as units to hold and feed the carton : * : blanks and units to glue and form the various folded regions to create a finished carton. I.. * 25

As detailed in GB 2381497 such units are typically independently mounted within the *.S machine necessitating separate load bearing frames. This is disadvantageous for a number of reasons. Firstly, conventional erecting machines are not compact and require significant factory floor space due to their large footprint. Secondly, such machines lack versatility as the various components are not readily interchangeable due to their independent support configuration.

What is required therefore is a carton processing machine that addresses the above problems.

The inventors provide a modular carton processing machine configured to provide versatility of carton processing and machine assembly. For example, a machine is provided to enable a user to readily interchange the various working components to satisfy specific requirements. Additionally, the present machine is compact and is designed to reduce the overall machine footprint in turn providing a cost saving on factory floor space.

The present invention utilises a common support frame configured to support a plurality of carton processing units. The support frame is further designed to provide an easy releasable attachment to an auxiliary support structure such as a conveyor unit. For example, one or a plurality of common support frames may be utilised by an operator at a single conveyor unit, with each support frame mounting a plurality of different carton processing units.

According to a first aspect of the present invention there is provided a carton processing machine comprising: a common support frame configured to support a plurality of carton processing units; a feeder magazine for holding and feeding preformed cartons, the magazine mounted on the support frame; an erecting station to receive the preformed cartons from the magazine and to fold regions of the cartons to provide erected cartons, the erecting station mounted on the support frame; and a transfer actuator for transferring the preformed cartons to the erecting station from the feeder magazine, the actuator mounted *:*::* on the support frame.

* ** * * S **..

Within this specification, reference to carton' includes any form of cardboard or plastic based article having any shape and configuration. The term includes box-like structures * being open or sealed and sleeve like structures designed to fit around an item for * * ** packaging. Reference to a preformed carton' includes substantially planar or non-planar : : : blanks that are preformed and optionally creased such that when processed by an * 30 automated processing machined the carton is erected being suitable for packaging, surrounding or containing one or a plurality of items.

Within this specification, reference to carton processing units' refers to a functional unit configured to perform a specific task during processing of a preformed carton blank. Such processing units are readily mountable upon the common support frame and are equally readily demountable so as to allow the interchanging of both the position and nature of the processing units relative to other processing units mounted at the common support frame.

Preferably, the machine further comprises mountings to mount the frame on an auxiliary support structure. The mountings may comprise a first pair of mountings positioned towards a first end of frame and a second pair of mountings positioned towards a second end of the frame. Optionally, the mountings may comprise nut and bolt arrangements together with suitable support struts to extend between the common support frame and the auxiliary support structure.

Preferably, the support frame comprises two elongate plates spaced apart along their length. Optionally, at least one cross-strut aligned transverse or perpendicular to the elongate plates and connecting the elongate plates may be incorporated to provide a rigid frame. The cross-struts may be formed integrally on non-integrally with the two elongate plates. Alternatively, the support frame may comprise any configuration suitable to mount a number of carton processing units. Such frames include solid plates of various sizes and configuration. One or more holes or voids may be formed in the plate to accommodate the various processing units and allow movement of the working components and cartons during processing operations. * ** * * *

* .. The feeder magazine, erecting station and transfer actuator are realisably mounted on the **** frame by releasable securing means. Such securing means may comprise nut and bolt : .: : : arrangements, securing clamps, pins or brackets as found in the art. Accordingly, different * processing units and importantly the different components of each processing unit may be * * ** removed, replaced and interchanged at the common support frame. **** ** *

* *: 30 Preferably, the feeder magazine and the erecting station are detachably mounted to extend from an upward facing side of the frame and the transfer actuator is mounted to extend from a downward facing side of the frame. Optionally, the machine further comprises a conveyor, realisably attached to the common support frame and configured to receive erected cartons from the erecting station and to transfer the erected cartons to additional carton processing units.

Preferably, the erecting station comprises: a plurality of upright carton-erecting walls; and a moveable head configured to move back and forth between the upright carton-erecting walls; wherein the head is configured to move downwardly to engage a preformed carton and to press the preformed carton downwardly between the carton-erecting walls to fold regions of the carton inwardly.

Preferably, the transfer actuator comprises at least one servo drive motor. Optionally, the actuator may comprise a pneumatic actuator, a belt drive or flighted chain as found in the art.

Optionally, the machine may comprise a gluing station positioned between the feeder magazine and the erecting station, the gluing station mounted on the common support frame. Additionally, the gluing station and erecting station may be arranged to process the preformed cartons in series, wherein the transfer actuator is configured to transfer the preformed cartons from the feeder magazine to the erecting station via the gluing station.

The present machine is also configurable without gluing stations for use with self-locking carton arrangements found in the art.

Optionally, the machine may be configured to be freestanding and accordingly comprises support legs configured to engage the floor. These support legs are mounted at the common support frame. Alternatively, the machine may be configured to be supported via : :, the auxiliary support structure such as a conveyor or other carton processing machine. The machine of the subject invention is attachable to any such auxiliary support structure via * the common support frame. **** ** *

*.: 30 Additionally, the common support frame may be fitted with additional guards to protect operators from the machine processing units and to mount suitable control devices such as a programmable logic controller (PLC). The present machine may comprise a plurality of PLCs to independently control the various processing units or a single PLC may be used to control collectively all the processing units including the feeder magazine, gluing station, erecting station and transfer actuator. Alternatively, the present machine may comprise a hard-wired control panel to provide the required electronic control of the various processing units.

A specific implementation of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which: figure 1 illustrates a side elevation view of a carton processing machine comprising a preformed carton feeder, a gluing station, an erecting station and a transfer actuator all mounted on a common support frame according to a specific implementation of the present invention; figure 2 illustrates a plan view of the carton processing machine of figure 1; figure 3 illustrates an end elevation view of the carton processing machine of figure 2; figure 4 illustrates a side elevation view of the carton processing machine of figure 3 positioned in series with a carton collating machine; figure 5 illustrates a plan view of the processing and collating machines of figure 4; * ** * * * figure 6 illustrates schematically the movement and processing of cartons and collated ***.

items processed by the machines of figure 5. * S. * * * ***.

figure 7 illustrates schematically the movement and processing of preformed cartons by the processing machine of figures ito 3. **.* S. *

* .: 30 Referring to figure 1, the carton processing machine comprises a feeder magazine 101, an erecting station 102, a transfer actuator 103 and a pair of gluing station 104 all mounted on a common support frame 100.

Feeder magazine 101 comprises a base support tray 106 to support a plurality of substantially planar preformed cartons. The preformed cartons are further held by dispensing face 105. A moveable arm 108, rotatably mounted at one end via axle 115 is configured to pivot back and forth about axle 115 between a substantially upright position A and a substantially horizontal position B. Feeder magazine 101 is mounted at a common support frame 100 via suitable mountings 107 extending from an upper face 119 of support frame 100. According to the specific implementation, feeder magazine 101 is mounted substantially at one end 202 of support frame 100 via mountings 107.

Spaced laterally from feeder magazine 101, erecting station 102 is mounted at common support frame 100 towards a second end 203 via suitable mountings 116, 127 and 128.

Erecting station 102 comprises a moveable head 113 supported at one end by two guide rods 124 positioned either side of a central actuating piston 125. Piston 125 is supported within a frame mounting 112 whilst guide rods 124 are supported by sub-frame 126. The head assembly is mounted on support frame 100 so as to be positioned above the upward facing surface 119 in a vertical direction but not over surface 119. Referring to figure 2, support frame 100 according to the specific implementation, comprises two elongate plates spaced apart along their length and aligned parallel to one another. The erecting station head 113 and associated components 112, 124, 125, 126 are mounted upon the upward * s. facing surface 119 of support frame 100 via two cross struts 205 alighted perpendicular to the elongate plates 100. Each cross strut 205 is releasable attached to frame 100 via nut and **..

bolt arrangements 116. * ** * . . *.**

An erecting boss 114 comprises an upward facing end 121 to receive the preformed cartons * * and a downward facing end 122 from which the erected cartons are dispensed onto, for example, a conveyor belt 400 referring to figure 5. Boss 114 comprises a through-bore * 30 extending between ends 121 and 122, the bore being defined by upright carton-erecting walls 204 to urge against a preformed carton to cause folding at various regions. Boss 114 is suspended from common frame 100 via support struts 127. Support struts 127 are mounted at inward facing surface 300 of support frame 100 as illustrated in figure 3.

A transfer actuator 103 is suspended from support frame 100 via suitable mountings 123 so as to be positioned below frame 100 in the vertical direction. Actuator 103 comprises a servo drive motor 129 to drive a pusher unit 110 back and forth along a guide channel 111.

Pusher unit 110 extends from guide channel 111, positioned below support frame 100, to a position above frame 100, in the vertical direction, in close proximity to two elongate guide rails 109. Guide rails 109 are positioned slightly elevated above frame 100, in the vertical direction, and internally of innermost surface 300. Guide rails 109 are configured to support a preformed carton as it is transferred by transfer actuator 103 from the feeder magazine 101 to the erecting station 102. Pusher unit 110 comprises two engaging fingers 206 configured to engage one edge of the preformed carton.

Elongate guide channel 111 is of a length sufficient to allow pusher unit 110 to transfer a preformed carton from feeder magazine 101 to erecting station 102. Unlike prior art erecting machines, transfer actuator 103 provides for the controlled and precise transfer of the preformed carton without the need for additional actuation means to provide the controlled delivery of the carton to the erecting station 102. As will be appreciated, it is important to ensure the preformed carton templates are delivered to the erecting station 102 at the correct speed and in a controlled manner so as to avoid slip' resulting in machine mis feed. * . * S S

S.:: By mounting the various machine processing units 101, 102, 103 and 104 on a common S...

mounting 100, the transfer of preformed cartons between the units can be easily and : .: . readily set-up, operated and adjusted. Importantly, common support frame 100 allows the * compact coupling of processing units 101, 102, 103 and 104 effectively minimising the * * ** distance by which the preformed cartons are transferred from feeder magazine 101 to erecting machine 102. This reduces the overall machine footprint and the amount of the * 30 different materials used to construct the processing machine. Also this provides a fully integrated piece of apparatus that, unlike conventional machines, does not required on-site modification to address compatibility problems associated with coupling different processing units within a single machine that are mounted on separate support frames.

Referring to figures 1 and 2, two gluing stations 104 are mounted at support frame 100 so as to be displaced above frame 100 in the vertical direction. Gluing stations 104 are positioned laterally between feeder magazine 101 and erecting station 102. Each gluing station 104 comprises a glue gun 117 with a dispensing end arranged to be downward facing in the direction towards frame 100. Each gluing station 104 is mounted upon upward facing side 119 of support frame 100, via mounts 118, to be aligned inside of each of the two elongate support plates 100 but on the outside of elongate guide rails 109.

According to the specific implementation, support frame 100 is formed by two elongate plates spaced apart along their length and aligned substantially parallel to one another. The plates are connected together via perpendicular aligned cross struts 205, 129 so as to provide a rigid frame structure. A first pair of releasable mountings 200 is provided at support frame 100 towards first end 202 and a second pair of mountings 201 is provided at support frame 100 towards second end 203. Mountings 200, 201 enable frame 100 and processing units 101, 102, 103 and 104 to be suspended or coupled to a suitable auxiliary support structure including, for example, a conveyor 400 illustrated with reference to figures 4 and 5. One or a plurality of programmable logic controllers (PLCs) (not shown) are used to control each of the processing units 101, 102, 103 and 104. The PLC(s) may comprise any conventional control device and configured to provide electronic control of the mechanical operation of the various processing units. * a S * a S...

Figures 4 and 5 illustrate the coupling of the processing machine of figures 1 to 3 with an : * . additional collating machine 402. Collating machine 402 comprises apparatus 403 configured to collate individual items for packaging within a preformed carton produced by erecting machine 102. The processing machine of figures 1 to 3 is coupled to the :: collating machine 402 via couple mountings 404 and 401. The processing machine of the * 30 subject invention is coupled to a carton conveyor unit 400 via mountings 401, 404 releasably connected to support frame 100. Conveyor unit 400, referring to figures 4 and 5 extends from under erecting station 102 at a position opposed to the downward facing end 122 of boss 114 (from which the erected cartons emerge) to collating machine 402.

An additional unit conveyor 500 supplies the individual units, to be packaged, to collating machine 402. As detailed with reference to figure 6, these individual units are collated by apparatus 403 which are then assembled and packaged within the preformed carton deposited and transported upon carton conveyor 400.

In use, individual boxed units 601 are supplied to collating machine 402 via conveyor 500.

The units are collated 602 by apparatus 403 and are formed into ordered, collated arrays 603. This array of units 603 is then transferred via a first directional movement 608 to position 604. The array of units 604 is then lowered 609 to position 605 onto the formed carton 600. Carton 600 comprises base portion 606 supported by carton conveyor 400.

Carton edges 607 extend vertically and perpendicular to base 606. The individual units 605 are held in position as an array of individual units by base 606 and edges 607 of carton 600.

Referring to figures Ito 7, a plurality of substantially planar preformed and pre-creased cartons are stored at feeder magazine 101 ready for supply to erecting station 102.

Referring to figure 7, during a single carton forming process 701, the preformed carton 702 held by feeder magazine 101 (position A) is transferred 705 from feeder magazine 101 by moveable arm 108, to position B supported in the horizontal plane by guide rails 109. Each .5. preformed carton 702 comprises a first flap 703 extending over the carton width and a S.:. second flap 704 extending over the length of the carton 702. * I..

* :2. The preformed carton supported by guiderails 109 is then displaced laterally by activation of servo drive motor 129 to cause transfer unit 110 and in particular fingers 206 to engage a trailing edge of the preformed carton 702 at position B. The carton is then pushed along :::: guiderails 109 in direction 706 to position C. On-route in direction 706, regions of the * 30 preformed carton pass directly underneath glue guns 117 which via a PLC (not shown), dispense glue onto appropriate portions in preparation for the folding process undertaken at erecting station 102. Transfer actuator 103 is configured to transfer preformed cartons 702 to a position directly underneath head 113 and immediately above boss 114. Engaging head 113 is then displaced vertically downward onto carton base 606 to force the preformed carton downwardly into the bore extending through boss 114 where flaps 703, 702 are urged against the carton-erecting walls 204 (direction 707, 708, 709, 710 of figure 7). As the preformed carton is forced by head 113 through boss 114, flaps 704 are bent upwardly and inwardly through positions D and E. Flaps 703 are then bent upwardly and inwardly as the preformed carton is forced further in the downward direction through boss 114 such that flaps 704, 703 overlap to form the final carton 600 at position G. The formed cartons, referring to figure 6 are then transferred in direction 711 along carton conveyor 400 ready to receive the array of individual tmits 604.

As illustrated with reference to figure 7, the present processing machined is capable of erecting preformed cartons having a plurality of different carton flap and crease configurations. For example, the processing series 712 of figure 7 involves the formation of carton 714 having a flap lid 713. The preformed carton 714 is processed according to the same process steps illustrated by series 701 to produce the final erected carton which, may be transferred for further processing andlor to receive packaging contents. * *S * * .* * *** * *

* ** * * IS * * * *.**

I

I I,.. * * ** I * I I * **

Claims

Claims 1. A carton processing machine comprising: a common support frame configured to support a plurality of carton processing units; a feeder magazine for holding and feeding preformed cartons, the magazine mounted on the support frame; an erecting station to receive the preformed cartons from the magazine and to fold regions of the cartons to provide erected cartons, the erecting station mounted on the support frame; and a transfer actuator for transferring the preformed cartons to the erecting station from the feeder magazine, the actuator mounted on the support frame.
2. The machine as claimed in claim 1 further comprising mountings to mount the frame on an auxiliary support structure.
3. The machine as claimed in claim 2 wherein the mountings comprise a first pair of mountings positioned towards a first end of the frame and a second pair of mountings positioned towards a second end of the frame.
4. The machine as claimed in any preceding claim wherein the support frame comprises two elongate plates spaced apart along their length and at least one cross-strut :: aligned transverse or perpendicular to the elongate plates and connecting the elongate plates to provide a rigid frame. S...
5. The machine as claimed in claim 4 wherein the cross-struts are formed integrally * with the two elongate plates.
6. The machine as claimed in claim 4 wherein the cross-struts are formed non-integrally with the two elongate plates.
7. The machine as claimed in any preceding claim wherein the feeder magazine, erecting station and transfer actuator are releasably mounted on the frame by releasable securing means.
8. The machine as claimed in any preceding claim wherein the feeder magazine and erecting station are mounted on au upward facing side of the frame and the transfer actuator is mounted on a downward facing side of the frame.
9. The machine as claimed in any preceding claim wherein the erecting station comprises: a plurality of upright carton erecting walls; and a moveable head configured to move back and forth between the upright carton-erecting walls; wherein the head is configured to move downwardly to engage a preformed carton and to press the preformed carton downwardly between the carton-erecting walls to fold regions of the carton inwardly.
10. The machine as claimed in any preceding claim further comprising a conveyor to receive erected cartons from the erecting station and to transfer the erected cartons to *:*::* 20 additional carton processing units.
ii. The machine as claimed in any preceding claim wherein the transfer actuator : .. comprises a servo drive motor. S...

S
12. The machine as claimed in any one of claims 1 to 10 wherein the transfer actuator *S..: : : : comprises a pneumatic actuator.
13. The machine as claimed in any one of claims Ito 10 wherein the transfer actuator comprises a belt or flighted chain.
14. The machine as claimed in any preceding claim further comprising a gluing station positioned between the feeder magazine and the erecting station, the gluing station mounted on the common support frame.
15. The machine as claimed in claim 14 wherein the feeder magazine, gluing station and erecting station are arranged to process the preformed cartons in series, wherein the transfer actuator is configured to transfer the preformed cartons from the feeder magazine to the erecting station via the gluing station.
16. The machine as claimed in any preceding claim comprising at least one programmable logic controller to control the feeder magazine, erecting station and transfer actuator.
17. The machine as claimed in any one of claims Ito 15 comprising a hard-wired control panel to control the feeder magazine, erecting station and transfer actuator. * ** * I * * S. S... * . S... * I. * I I *IIII S.. S... * I *.*. *. . S*I SI