GB2546240A

GB2546240A - Carton forming

Info

Publication number: GB2546240A
Application number: GB1520753.3A
Authority: GB
Inventors: Hayward David
Original assignee: LINKX SYSTEMS Ltd
Current assignee: LINKX SYSTEMS Ltd
Priority date: 2015-11-24
Filing date: 2015-11-24
Publication date: 2017-07-19
Anticipated expiration: 2035-11-24
Also published as: GB201520753D0; GB2546240B

Abstract

A carton forming machine (1) including a pair of opposed magazine assemblies (2), aretriever assembly (3) for selectively retrieving a carton blank (B1, B2) from one of the magazine assemblies (2), carton forming means (4, 5, 6, 7, 8) and a controller operatively connected to all of the assemblies for operating the machine (1). Each of the magazine assemblies (2) is configured to receive respective carton blank stacks each for making a different carton variant (B1, B2). The controller is configured to receive a plurality of carton variant requests and, on receipt of each request, to cause the retriever assembly (3) to retrieve one carton blank (B1, B2) corresponding to the requested carton variant (B1, B2) and to cause the carton forming means (4, 5, 6, 7, 8) to form a carton therefrom. The machine may comprise a carton sizing machine having a controller, one or more cutters, one or more markers and measuring means configured to determine the footprint of an open top carton and the height of objects contained within the carton. The machine may include carton opening means and each of the retriever and the opening means comprises a suction device for gripping opposite sides of an exposed carton blank.

Description

CARTON FORMING

This invention relates generally to carton forming. More specifically, although not exclusively, this invention relates to a carton forming machine, system and method, to a packaging system including such a machine and a packaging method including such a carton forming method.

In the field of made-to-order packages, orders are placed for varying product types and quantities and packages containing such products must be prepared for shipment. These packages can result in an infinite number of combinations of products that are placed in standard sized cartons. Any particular product combination will occupy a predetermined size and volume within the carton and as package shipment costs are generally dependent upon both the weight and dimensions of the package to be shipped, selection of a suboptimal carton size can have a significant cost impact.

Known solutions to this issue involve the use of a single carton blank size that is modified in some way to suit the contents to be packed. EP0645309, for example, discloses a cartoning system in which the erected carton is cut to a height equivalent to the contents to be packed. The excess material is then discarded and a lid is placed on the open top, which results in wasted material. FR2612885 proposes a carton blank in which upper foldable panels are provided with a plurality of fold lines so that the most appropriate fold line can be selected to suit the height of the contents to be packed. The adaptability of such cartons is limited to the intervals between the fold lines, bespoke carton blanks are required, which can be expensive, and the multiple fold lines can cause problems in the erection and closure of the cartons in use.

Other solutions propose modifying the carton with knowledge of its contents. For example, FR2606367 discloses a cartoning system in which the carton blanks are creased before they are erected and filled on the basis of a known configuration of contents to be packed. Similarly, US3953956 describes a cartoning system in which a prefilled open top carton is scored at the height of the contents, the upper portion of the vertical corners are cut down to the level of the score lines to create flaps defined by the score lines, cut corners and upper edge and the side flaps are cut to less than half the width of the carton so they do not overlap when folded down. WO2013182845 to the present applicant discloses a carton sizing system comprising cutters, markers and measuring means configured to determine the footprint of an open top carton and the height of objects contained within the carton. The system positions the cutters based on the footprint, cuts vertical corner edges of the carton based on the height of the objects, positions the markers based on the footprint and height of the objects and scores or creases vertical walls of the carton between the vertical edges to define foldable panels. Whilst this arrangement is exceptionally adaptable, the applicant has determined that there remains a need for a carton forming machine that enables a system to be configured which further simplifies and/or enhances the ease of packaging in such made-to-order applications.

Accordingly, a first aspect of the invention provides a carton forming machine comprising at least two magazines for receiving respective carton blank stacks each for making a different carton variant, a retriever for selectively retrieving a carton blank from one of the magazines, carton forming means for forming a carton blank retrieved by the retriever and a controller for receiving one or more, e.g. a plurality of, carton variant requests, wherein the controller is configured on receipt of the or each request to cause the retriever to retrieve a carton blank, e.g. one carton blank, corresponding to the requested carton variant and to cause the carton forming means to form a carton therefrom.

Thus, the invention provides a machine capable of forming an individual carton from any one of multiple different carton variants on demand.

Two of the magazines may be opposed. Preferably, the at least two magazines comprise at least one pair of magazines, which may be opposed. The retriever may be movable between the opposed magazines.

Another aspect of the invention provides a carton forming machine comprising a pair of opposed magazines for receiving respective carton blank stacks each for making a different carton variant, a retriever movable between the opposed magazines for selectively retrieving a carton blank from one of the magazines, carton forming means for forming a carton blank retrieved by the retriever and a controller for receiving a carton variant request, wherein the controller is configured on receipt of the request to cause the retriever to retrieve a carton blank corresponding to the requested carton variant and to cause the carton forming means to form a carton therefrom.

The provision of opposed magazines enables more efficient carton forming and also enables the machine to form cartons from both left handed and right handed carton blanks.

The at least two magazines may comprise three or more, for example four or more, e.g. five or more, such as six or more, magazines. The machine may comprise two or more magazine pairs, which may be aligned and/or arranged consecutively.

The retriever may be movable between the at least two magazines, for example between the or each pair of magazines, to selectively retrieve carton blanks therefrom. Whilst it is preferable that the machine comprises pairs of opposed magazines, it is also envisaged that the machine comprises an odd number of magazines.

The retriever may comprise a shuttle or carriage or arm, which may be mountable on one or a pair or more rails. The retriever may comprise a gripper, for example a suction or vacuum device, hereinafter suction device, or any other suitable gripping means. The retriever may comprise two or more grippers, for example a gripper on each of its sides, e.g. its magazine-facing sides, for gripping a carton blank from a respective magazine, e.g. a facing magazine.

The machine may comprise a carton opening means, which may be associated with the retriever or associated with at least one or each magazine. The carton opening means may be suitable for opening the carton blank as it is retrieved by the retriever. The carton opening means may be suitable for retaining part of an exposed carton blank, for example such that on retrieval thereof, in use, by the retriever, the carton blank is opened by movement of the retriever, e.g. away from the magazine and/or toward the other magazine. The carton opening means may comprise a gripper, for example a suction device or any other suitable gripping means.

In embodiments, each of the retriever and the opening means comprises a gripper, e.g. a suction device, for gripping opposite sides of an exposed carton blank. The controller may be configured, e.g. on receipt of a request for a carton variant, to cause the grippers to grip opposite sides of an exposed carton blank. The controller may be configured, e.g. on receipt of a request for a carton variant, to cause the retriever to move toward the carton forming means, e.g. thereby opening the carton blank. The controller may be configured, e g. on receipt of a request for a carton variant, to cause the carton forming means to form a carton therefrom.

Another aspect of the invention provides a carton forming machine comprising a magazine for receiving a stack of carton blanks, a retriever for retrieving a carton blank from the magazine, carton opening means for opening a carton blank, carton forming means for forming a carton blank retrieved by the retriever and a controller for receiving a carton request, wherein each of the retriever and the carton opening means comprises a gripper, e.g. a suction device, for gripping opposite sides of an exposed carton blank of the stack of carton blanks received by the magazine, the controller being configured on receipt of the request to cause the grippers to grip opposite sides of an exposed carton blank, to cause the retriever to move away from the stack or from the magazine thereby opening the carton blank and to cause the carton forming means to form a carton therefrom.

The provision of grippers on opposite sides of the carton blank improves the ability of the machine to open reliably and consistently carton blanks as they are retrieved.

The carton opening means may comprise an opening member, e.g. against which an end panel of the carton blank is urged, in use, when or as the carton blank is retrieved by the retriever, for example thereby to open the carton blank. The opening means may comprise an opening member associated with each magazine. The opening means may be configured or operable to enable both left handed and right handed carton blanks to be erected.

In embodiments comprising opposed magazines, the opening means may comprise an opening member associated with each magazine both of which may be on one side of the retriever. A first opening member may be on a first side of a first of the opposed magazines and/or a second opening member may be on a second side of a second of the opposed magazines. Thus, the machine may be configured such that one of the magazines can be loaded with left handed blanks and the other of the magazines can be loaded with right handed blanks.

In embodiments, the opening members are on a leading or downstream side of the retriever. In embodiments, the opening members are on a trailing or upstream side of the retriever. In embodiments, the machine or opening means comprises a pair of opening members on a leading or downstream side of the retriever and a pair of opening members on a trailing or upstream side of the retriever, for example wherein one of each pair is associated with each magazine. One or more, e.g. a first pair, of the opening members may be stationary and/or arranged such that movement, in use, of the retriever causes an end panel of a carton blank to be urged against one of the opening members, e.g. thereby to open the carton blank. One or more, e.g. a second pair, of the opening members may be deployable, for example movable or rotatable between a retracted position and a deployed position. In the deployed position, the opening member or members may be configured or operable to be urged against an end panel of the carton blank, e.g. thereby to open the carton blank.

In embodiments, the carton opening means comprises an opening member on or deployable to each side of the retriever against which an end panel of the carton blank is urged, in use, when or as the carton blank is retrieved by the retriever thereby to open the carton blank.

Another aspect of the invention provides a carton forming machine comprising a magazine for receiving a stack of carton blanks, a retriever for retrieving a carton blank from the magazine, carton opening means for opening a carton blank, carton forming means for forming a carton blank retrieved by the retriever and a controller configured to receive a carton request and, on receipt thereof, to cause the retriever to retrieve a carton, to cause the opening means to open the carton blank and to cause the carton forming means to form a carton from the open carton blank, wherein the carton opening means comprises an opening member on or deployable to each side of the retriever against which an end panel of the carton blank is urged, in use, when or as the carton blank is retrieved by the retriever thereby to open the carton blank.

The opening member may comprise a guide member, which may comprise a plate and/or may be angled or curved. Where the opening member is deployable, it may comprise a deployable arm. In embodiments, the guide plate is on a first or leading or downstream side of the retriever and/or the deployable arm is on a second or trailing or upstream side of the retriever.

The machine may comprise a carton blank raising means, which may be associated with at least one or each magazine. The or each carton blank raising means may be configured to raise, in use, an exposed carton blank, for example prior to its retrieval by the retriever, e.g. thereby to separate it from one or more other carton blanks in the stack. In embodiments, the gripper or suction device of the opening means is configured to grip, in use, an upper and/or exposed portion of the raised blank, for example on the opposite side thereof to the retriever.

Another aspect of the invention provides a carton forming machine comprising a magazine for receiving a stack of carton blanks, carton blank raising means associated with the magazine for raising an exposed carton blank of the stack, a retriever for retrieving a raised carton blank, carton forming means for forming a carton blank retrieved by the retriever and a controller for receiving a carton request, wherein the controller is configured on receipt of a request to cause the carton blank raising means to raise an exposed carton blank, to cause the retriever to retrieve the raised carton blank and to cause the carton forming means to form a carton therefrom.

The carton blank raising means may comprise a pusher, e.g. for pushing the bottom of an exposed carton blank upwardly. The pusher may comprises a jack. The pusher or jack may include a lifting foot, e.g. projecting therefrom and/or for engaging a lower edge of an exposed carton blank. The pusher or jack may comprise an actuator or jacking actuator, e.g. for urging or forcing the lifting foot, for example upwardly and/or against the lower edge of the exposed carton blank. The actuator may comprise a mechanical, electromechanical and/or fluid-driven actuator, for example a hydraulic or pneumatic actuator. The pusher or jack preferably comprises a jacking cylinder, which may be hydraulically or pneumatically actuated, for urging or forcing the lifting foot upwardly and/or against the lower edge of the exposed carton blank. The pusher or jack may comprise a stop, for example against which the exposed carton blank may abut, e.g. for aligning the lower edge thereof with the foot prior to lifting. The lifting foot may be adjustable with respect to the actuator or cylinder or stop, e.g. for accommodating different carton blank thicknesses.

The machine may comprise an abutment, e.g. for inhibiting upward movement of one or more carton blanks adjacent the exposed carton blank, for example whilst allowing upward movement of the exposed carton blank. The abutment may be mounted to or otherwise associated with the carton opening means, for example mounted to and/or movable with the gripper or suction device that is configured to grip an upper and/or exposed portion of a raised blank.

At least one or each magazine may be movable or adjustable horizontally and/or vertically. At least one or each magazine may be movable or adjustable vertically to adjust the position of a carton blank stack received thereby, for example relative to the retriever. At least one or each magazine may comprise a lift mechanism, e.g. a scissor lift, for adjusting the vertical position of the carton blank stack received thereby. At least one or each magazine may be movable or adjustable horizontally to accommodate carton blanks of different widths. In embodiments, at least one or each magazine comprises a cradle, e.g. for receiving a stack of carton blanks, and/or a pair of carton blank rails, e.g. along which a stack of carton blanks is conveyable. At least one of the carton blank rails may comprise a feed means or mechanism, e.g. for conveying the carton blank stack along the rail. At least one of the carton blank rails may be movable or adjustable relative to one another, e.g. to accommodate carton blanks of different widths. In embodiments, the rails are movable toward or away from one another and/or movable together relative to a magazine frame.

The machine may comprise a conveyor, e.g. for conveying a partially formed carton blank along a conveying direction. At least one or each magazine may be configured to receive carton blanks with their major surfaces parallel to the conveying direction. It will be appreciated that the terms leading and downstream sides or panels as used herein refer to panels or sides that are leading or downstream in the conveying direction and that the terms trailing and upstream panels or sides as used herein refer to panels or sides that are trailing or upstream in the conveying direction.

The carton forming means may comprise a pair of end flap folders, which may be aligned with the conveyor and/or may be suitable for folding, in use, end flaps of a carton retrieved by the retriever. One of, e.g. a first of, the end flap folders may be on a trailing side of the retriever and/or another of, e.g. a second of, the end flap folders may be on the leading side of the retriever.

The machine may comprise a carton transfer shuttle, which may be movable along the conveying direction. The carton transfer shuttle may include the first end flap folder, e.g. for folding the trailing end flap. The carton transfer shuttle may include a gripper, e.g. for gripping a partially formed carton blank from the retriever. The carton transfer shuttle may be configured or suitable for transferring the or a partially formed carton blank to the conveyor.

The machine may comprise a carton closer, which may be beneath the conveyor and/or including the second end flap folder. The machine or carton closer or conveyor may comprise a pair of side flap folders, at least one or each of which may extend along at least part of the conveyor, e.g. for folding, in use, side flaps of a carton conveyed along the conveyor. The carton closer may comprises a glue or tape applicator for securing two or more of the flaps together, for example the two side flaps, the two end flaps or one and/or each end flap to one or each side flap.

One or more or each of the flap folders may be movable, e.g. rotatable, between a retracted position and a deployed position. The or each movable flap folder may comprise a plate and/or may extend substantially horizontally in the deployed position. The or each movable flap folder may depend and/or extend downwardly in the retracted position.

The machine may comprise a flap compressor or flap compression assembly, which may be downstream of the flap folders and/or the carton closer. The flap compressor may be located above the conveyor and/or mounted to the frame. The flap compressor may comprise a compression plate, which may be mounted to a compression cylinder.

Another aspect of the invention provides a packaging system comprising a carton forming machine, e.g. as described above.

The system may comprise a carton variant management means, e.g. for generating and/or sending to the carton forming machine a request for a carton variant.

The system may comprise one or more loading stations each of which may include one or more carton escrow bays, e.g. for receiving a carton variant. The carton variant management means may comprise a carton stock management system. The carton variant management means or carton stock management system may comprise detection means, e.g. for detecting a shortfall in one of the carton variants at the or each or at least one or more of the loading stations. The carton variant management means or carton stock management system may comprise may be configured to generate and/or send, e.g. on detection of such a shortfall, to the carton forming machine a request for that carton variant.

Additionally or alternatively, the carton variant management means may comprises an order management system. The carton variant management means or order management system may be configured to receive an order, e.g. for a plurality of objects, and/or to select based on the or a plurality of objects a carton variant and/or to generate and/or send to the carton forming machine a request for a carton variant, e.g. that carton variant.

The system may comprise a carton sizing machine, which may have one or more features described in WO2013182845, the contents of which are incorporated herein by reference. The carton sizing machine may comprise one or more of a controller, one or more cutters, one or more markers and measuring means, which may be configured to determine the footprint of an open top carton and/or the height of objects contained within the or an open top carton. The controller may be configured to position, in use, the cutters based on the footprint and/or to cut vertical corner edges of the carton based on the height of the objects. The controller may be configure to position, in use, the markers based on the footprint and/or the height of the objects and/or to score or crease vertical walls of the carton, e.g. between the vertical edges, for example to define foldable panels.

Another aspect of the invention provides a magazine assembly, e.g. for use in a machine or system as described above. The assembly may comprise a cradle, e.g. for receiving a stack of carton blanks, and/or a carton blank raising means, which may be at or adjacent one of its ends. The carton blank raising means may be configured to raise, in use, an exposed carton blank, e.g. prior to its retrieval by a retriever, for example thereby to separate it from one or more other carton blanks in the stack.

Another aspect of the invention provides a method of forming a carton using a carton forming machine, e.g. as described above.

The method may comprise forming a carton using a carton forming machine having at least two magazines for receiving respective carton blank stacks each for making a different carton variant, the method comprising receiving a plurality of carton variant requests and, in response to each request, causing a retriever of the machine to retrieve one carton blank from one of the magazines which corresponds to the requested carton variant and causing a carton forming means of the machine to form a carton therefrom.

The method may comprise raising, e.g. using a carton blank raising means, a carton blank to be retrieved, for example prior to its retrieval by the retriever, thereby to separate it from one or more other carton blanks in the stack.

The method may comprise forming a carton using a carton forming machine having a pair of opposed magazines for receiving respective carton blank stacks each for making a different carton variant, the method comprising receiving a carton variant request and, in response to the request, causing a retriever movable between the pair of opposed magazines to retrieve a carton blank corresponding to the requested carton variant and to cause the carton forming means to form a carton therefrom.

The method may comprise forming a carton using a carton forming machine having a magazine for receiving a stack of carton blanks, the method comprising receiving a carton request and, in response to the request, causing grippers, e.g. suction devices, to grip opposite sides of an exposed carton blank of the stack, causing a retriever to move away from the stack and/or the magazine thereby opening the carton blank and causing a carton forming means to form a carton therefrom.

The method may comprise forming a carton using a carton forming machine having a magazine for receiving a stack of carton blanks, the method comprising receiving a carton request and, in response to the request, causing a retriever to retrieve a carton blank and selectively urging an end panel of the carton blank against an opening member on one of a leading or a trailing side of the retriever based on the configuration of the carton blank thereby to open the carton blank.

The method may comprise forming a carton using a carton forming machine having a magazine for receiving a stack of carton blanks, the method comprising receiving a carton request and, in response to the request, causing the carton blank raising means to raise an exposed carton blank, causing a retriever to retrieve the raised carton blank and causing a carton forming means to form a carton therefrom.

The method may comprise gripping, e.g. using a gripper or suction device of the retriever, a first side of the raised carton blank and/or gripping, e.g. using a gripper or suction device of the magazine an upper, exposed portion of the raised blank, which may be on the opposite side thereof to the retriever. The method may comprise moving the retriever away from the magazine such that the carton blank is opened.

For the avoidance of doubt, any of the features described herein apply equally to any aspect of the invention. For example, the machine, system or assembly according to any of the aforementioned aspects may comprise any one or more features of any one of the others relevant thereto and/or the method may comprise any one or more features or steps relevant to one or more features of the machine, system or assembly.

Another aspect of the invention provides a computer program element comprising and/or describing and/or defining a three-dimensional design for use with a simulation means or a a three-dimensional additive or subtractive manufacturing means or device, e.g. a three-dimensional printer or CNC machine, the three-dimensional design comprising an embodiment of one of the components described above. A further aspect of the invention provides a computer program element comprising computer readable program code means for causing a processor to execute a procedure to implement one or more steps of the aforementioned method. A yet further aspect of the invention provides the computer program element embodied on a computer readable medium. A yet further aspect of the invention provides a computer readable medium having a program stored thereon, where the program is arranged to make a computer execute a procedure to implement one or more steps of the aforementioned method. A yet further aspect of the invention provides a control means or control system or controller comprising the aforementioned computer program element or computer readable medium.

For purposes of this disclosure, and notwithstanding the above, it is to be understood that any controller(s), control units and/or control modules described herein may each comprise a control unit or computational device having one or more electronic processors. The controller may comprise a single control unit or electronic controller or alternatively different functions of the control of the system or apparatus may be embodied in, or hosted in, different control units or controllers or control modules. As used herein, the terms “control unit” and “controller” will be understood to include both a single control unit or controller and a plurality of control units or controllers collectively operating to provide the required control functionality. A set of instructions could be provided which, when executed, cause said controller(s) or control unit(s) or control module(s) to implement the control techniques described herein (including the method(s) described herein). The set of instructions may be embedded in one or more electronic processors, or alternatively, may be provided as software to be executed by one or more electronic processor(s). For example, a first controller may be implemented in software run on one or more electronic processors, and one or more other controllers may also be implemented in software run on or more electronic processors, optionally the same one or more processors as the first controller. It will be appreciated, however, that other arrangements are also useful, and therefore, the present invention is not intended to be limited to any particular arrangement. In any event, the set of instructions described herein may be embedded in a computer-readable storage medium (e.g., a non-transitory storage medium) that may comprise any mechanism for storing information in a form readable by a machine or electronic processors/computational device, including, without limitation: a magnetic storage medium (e.g., floppy diskette); optical storage medium (e.g., CD-ROM); magneto optical storage medium; read only memory (ROM); random access memory (RAM); erasable programmable memory (e.g., EPROM ad EEPROM); flash memory; or electrical or other types of medium for storing such information/instructions.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. For the avoidance of doubt, the terms “may”, “and/or”, “e.g.”, “for example” and any similar term as used herein should be interpreted as non-limiting such that any feature so-described need not be present. Indeed, any combination of optional features is expressly envisaged without departing from the scope of the invention, whether or not these are expressly claimed. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:

Figure 1 is perspective view of a carton forming machine according to one embodiment of the invention with the guards removed;

Figure 2 is a top view of the machine of Figure 1;

Figure 3 is a perspective view of part of one of the magazine assemblies of the machine of Figures 1 and 2 from the loading side;

Figure 4 is a perspective view of the part of the magazine assembly of Figure 3 shown from the retrieving side;

Figure 5 is an expanded view of one of the jack assemblies of the magazine assembly of Figures 3 and 4;

Figure 6 is a perspective view of the retriever assembly of the machine of Figures 1 and 2;

Figure 7 is a perspective view of the retriever assembly of Figure 6 with the bracing plate assembly omitted and with the vacuum devices repositioned;

Figure 8 is a perspective view of the carton transfer shuttle assembly of the machine of Figures 1 and 2;

Figure 9 is a perspective view of the flap folding and gluing assembly of the machine of Figures 1 and 2;

Figure 10 is a perspective view of the underside of the flap folding and gluing assembly of Figure 9; and

Figure 11 is a top view of a carton forming machine according to another embodiment of the invention, which incorporates two pairs of magazine assemblies.

Referring now to Figures 1 and 2, there is shown a carton forming machine 1 including a pair of opposed magazine assemblies 2, a retriever assembly 3 for selectively retrieving a carton blank B1, B2 from one of the magazine assemblies 2, a carton transfer shuttle assembly 4, a flap folding and gluing assembly 5, a conveyor assembly 6 and a flap compression assembly 7. The machine 1 also includes a frame 10 to which all of the assemblies are mounted and a controller 11 that includes a human machine interface (HMI) 12 and that is operatively connected to all of the assemblies for operating the machine. Each of the magazine assemblies 2 are configured to receive respective carton blank stacks each for making a different carton variant. The controller 11 is configured to receive a carton variant request and on receipt thereof to cause the retriever assembly 3 to retrieve a carton blank B1, B2 from the appropriate magazine assembly 2 to form a carton corresponding to the requested carton variant.

In this embodiment, the first carton blank B1 is left handed and the second carton blank B2 is right handed. As illustrated in Figure 11, a left handed carton blank B1 has its vertical crease VC left of centre, creating a main panel MP on the right side and a shorter, end panel on the left side. Contradistinctively, a right handed carton blank B2 has its vertical crease VC right of centre, creating a main panel MP on the left side and a shorter, end panel on the right side. For simplicity, the carton blanks B1, B2 are shown to have substantially the same dimensions and configuration, but these may have different dimensions, different textual or graphical matter printed thereon and/or one or both may be configured to form an open top carton (i.e. without foldable top panels). As will be understood by the skilled person, there are a number of circumstances in which left handed carton blanks B1 cannot be formed using a machine configured to form right handed carton blanks B2. These include, inter alia, when the cartons to be formed have textual or graphical matter having an intended, upright orientation and/or when the carton blank B1, B2 is configured to form an open top carton. The machine 1 according to the present invention is configured to accommodate left handed carton blanks B1 in a first magazine assembly 2 (on the right in Figure 2) and right handed carton blanks B2 in a second magazine assembly 2 (on the left in Figure 2). However and as will be explained further below, each magazine assembly 2 of the machine 1 is actually able to accommodate both left and right handed carton blanks B1, B2.

Each of the magazine assemblies 2 is movable vertically by a scissor lift SL. One of the magazine assemblies 2 is shown in more detail in Figures 3 to 5 and includes a cradle 20 formed by a pair of support rails 21 movably connected together by transverse guide bars 21a. Each of the support rails 21 includes a respective pusher feed assembly 22 at a loading end thereof for advancing a carton blank stack received thereon. The pusher feed assembly 22 includes a carriage 23 and a post 24 extending from the carriage 23. The carriage 23 is movably mounted with respect to the support rail 21 and is driven therealong by a drive assembly (not shown) incorporated within the support rail 21.

Each of the support rails 21 also includes a jack assembly 25 at a retrieving end thereof for raising an exposed, leading carton blank B1, B2 of the stack. In Figures 3 and 4, the carton blank B1, B2 is shown in a raised position. The jack assembly 25 includes a jacking cylinder 26 that is straddled by lifting member 27 having an inverted horseshoe shape with a pair of feet 27a projecting from its lower, free ends. The jack assembly 25 also includes a stop in the form of a bracing surface 25a perpendicular to the upper surface of the support rail 21 and against which the carton blank stack is urged by the pusher feed assembly 22. The feet 27a of the lifting member 27 project from the bracing surface 25a in a direction parallel to the support rail 21 such that they lie beneath the exposed, leading carton blank B1, B2 of the stack when the jacking cylinder 26 is in a lowered condition, shown in Figure 5. The lifting member 27 is adjustably secured to a pair of spaced piston rods of the jacking cylinder 26 by fasteners received in oval slots 27b of the lifting member 27 to keep it aligned as it is moved by the jacking cylinder 26. The oval slots 27b enable adjustment of the extent to which the feet 27a project from the jacking assembly 25 to enable different carton blank thicknesses to be accommodated. It will be appreciated that, in embodiments, this manual adjustment means may be replaced with an automatic adjustment mechanism.

Each of the magazine assemblies 2 also includes a frame 28 with side members 28a each of which is connected at one of their ends to a respective vertical member 28b and a cross member 28c joining the upper end of each vertical member 28b. An adjustment wheel 29 is mounted adjacent the free end of each side member 28a to a ball screw 29a movably connecting the side member 28a to a respective one of the rails 21. The adjustment wheels 29 enable manual adjustment of the position of the rail 21 relative to the side member 28a, although an automated adjustment mechanism is also envisaged.

Each of the magazine assemblies 2 also includes a carton blank retaining vacuum element 80 forming part of a carton opening means 8, which will be discussed in more detail below. The carton blank retaining vacuum element 80 is mounted to the end of a vertical arm 81 adjustably secured to the cross member 28c by a screw threaded adjustment lever 81a, although an automated adjustment mechanism is also envisaged. Whilst not shown, it is also envisaged that the carton blank retaining vacuum element 80 may comprise a plate depending therefrom to provide an abutment for inhibiting upward movement of one or more carton blanks adjacent the exposed carton blank whilst allowing upward movement of the exposed carton blank B1, B2. It is also envisaged that the plate incorporates or is operatively connected to a sensor for detecting a force exerted thereon by any such carton blanks B1, B2.

The retriever assembly 3 includes a shuttle 30 movable relative to a base 31 along a pair of parallel spaced rails 32 by a ball screw 33 driven by an electric drive mechanism 34. The drive mechanism 34 includes an electric motor 34a, which drives via a belt 34b a gear 33a secured to an end of the ball screw 33. The shuttle 30 includes a carriage 35 including a base plate 35a with a pair of linear bearings 35b on a lower side thereof that slidingly engage the rails 32 and an upstanding bracket 35c mounted on an upper side thereof. The shuttle 30 also includes two pairs of vertically spaced guide shafts 36a, 36b extending horizontally from the upright bracket 35c and orthogonally with respect to the rails 32. The shaft pairs 36a, 36b are secured together by a guide shaft plate 36c at their free ends. The shuttle 30 also includes a pair of gripper carriages 37a, 37b each of which runs along a respective one of the guide shaft pairs 36a, 36b. In this embodiment, each of the gripper carriages 37a, 37b includes a threaded lever 37c for releasably engaging one of the guide shafts 36a, 36b to fix its position, but an automated adjustment mechanism is also envisaged.

The upright bracket 35c includes magazine facing sides each of which carries a lower vacuum element 85a, 86a and an upper vacuum element 85b, 86b. The magazine facing sides of the upright bracket 35c also include a vertical slot within which the upper vacuum element 85b, 86b may be installed and adjusted to accommodate carton blanks of various sizes. Each of the gripper carriages 37a, 37b also includes a magazine facing side carrying a respective lower vacuum element 85c, 86c and a respective upper vacuum element 85d, 86d. The magazine facing side of each gripper carriage 37a, 37b also includes a vertical slot within which the upper vacuum element 85d, 86d may be installed and adjusted to accommodate carton blanks of various sizes. In this embodiment, the vacuum elements 85a, 85b, 85c, 85d, 86a, 86b, 86c, 86d are releasably secured by threaded clamping arrangements, but an automated adjustment mechanism is also envisaged.

The shuttle 30 also includes a bracing plate 38 secured on each magazine facing side to both the upright bracket 35c and the guide shaft plate 36c and includes a slot 38a for accommodating the upper vacuum element 85d, 86d of each gripper carriage 37a, 37b. Each gripper carriage 37a, 37b includes a rotary folding arm 39 mounted on the opposite side thereof to the upright bracket 35c and driven by a rotary cylinder 39a.

Referring now to Figure 8, the carton transfer shuttle assembly 4 includes a shuttle 40 movable relative to a base 41 along a pair of parallel spaced rails 42 by a ball screw 43 driven by an electric drive motor 44. The shuttle 40 includes a carriage 45 having a base plate 45a with a pair of linear bearings 45b on a lower side thereof that slidingly engage the rails 42 and an upstanding bracket 45c mounted on an upper side thereof. The carton transfer shuttle assembly 4 also includes a rotary folding bracket 46 shown in a first, vertical position flush with the upstanding bracket 45c, but deployable to a second, horizontal position by an actuating cylinder. The carton transfer shuttle assembly 4 also includes a lower vacuum element 47a, an upper vacuum element 47b and an upper support 48 above the upper vacuum element 47b. As above, the position of the upper vacuum element 47b may be installed and adjusted to accommodate carton blanks of various sizes. In this embodiment, the upper vacuum element 47b is releasably secured to one of three holes 49 in the upstanding bracket 45c by a threaded clamping arrangements, but an automated adjustment mechanism is also envisaged.

Referring now to Figures 9 and 10, the flap folding and gluing assembly 5 includes a glue station 50 with a feed tube 50a feeding a glue applicator 50b included within a central folding station 51. The central folding station 51 includes an end flap folding bracket 52 shown in a lowered position extending downwardly, but is deployable to a second, horizontal position by an actuating cylinder 52a. The flap folding and gluing assembly 5 also includes a pair of side folding stations 53, which are movable toward and away from one another by an automated adjustment assembly 53a (shown in Figure 2). Each side folding station 53 includes a conveyor 54 incorporating a conveying belt 54a driven by an electric motor 54b and a side flap folding bracket 56 beneath the conveyor 54 that is operated by a rotary cylinder 56a. Mounted to each side folding station 53 is a curved case breaker guide plate 87 for guiding an end panel of a carton blank B1, B2 to be opened.

Referring back to Figure 2, the conveyor assembly 6 includes a pair of side conveyors 60 similar to the conveyors 54 of the side folding stations 53, whose relative positions are also adjustable by an automated adjustment assembly 61. The flap compression assembly 7 (shown in Figures 1 and 2) is located directly above the conveyor assembly 6, is mounted to a crossbeam 70 of the frame 10 and includes a compression plate 71 mounted to a compression cylinder 72.

In use, the adjustment wheels 29 are operated to space the rails 21 to accommodate the width of a carton blank stack to be received on the support rails 21. The scissor lift SL of each magazine is also operated to position the carton blank stack at the appropriate vertical position. The stack is then placed on the support rails and is advanced therealong by the pusher feed assembly 22 until it braces against the bracing surface 25a of the jack assembly 25. The adjustment wheels 29 are then operated again to fine tune the position of the stack until the vertical crease VC on the loading side of the exposed carton blank B1, B2 is aligned with a datum edge DE of the retriever assembly 3 shown in Figure 6. This ensures that the vacuum elements 85a, 85b, 85c, 85d, 86a, 86b, 86c, 86d will all grip parts of the main panel on the retrieving side of the exposed carton blank B1, B2. The position of the lifting member 27 is adjusted to suit the thickness of the carton blanks B1, B2 and the position of the vacuum element 80 of the magazine 2 is positioned as required. The positions of the vacuum elements 85a, 85b, 85c, 85d, 86a, 86b, 86c, 86d of the retriever shuttle 30 are also adjusted to suit the carton blanks B1, B2.

The jack assembly 25 is then operated such that the feet 27a raise the exposed carton blank B1, B2 and, in one example, operation of the machine 1 involves the following steps: i) the controller 11 receives a request for a carton variant corresponding to one of the carton blanks B1 or B2; ii) the retriever shuttle 30 moves toward the appropriate carton blank B1 or B2 in one of the magazines 2 until the vacuum elements 85a, 85b, 85c, 85d or 86a, 86b, 86c, 86d on the facing side contact the carton blank B1 or B2; iii) the vacuum elements 85a, 85b, 85c, 85d or 86a, 86b, 86c, 86d of the retriever shuttle 30 and the vacuum element 80 of the magazine 2 on either side of the selected carton blank B1 or B2 are energized to grip opposite sides of the carton blank B1 or B2; iv) the retriever shuttle 30 is then moved away from the magazine 2 such that the carton blank B1 or B2 begins to open; v) the vacuum element 80 of the magazine 2 is de-energized and continued movement of the retriever shuttle 30 causes the shorter, end panel EP on the retrieving side of the carton blank B1 or B2 to contact the case breaker guide plate 87, thereby urging the carton blank B1 or B2 to a fully open condition; vi) optionally, the rotary folding arm 39 may be deployed to ensure that the carton remains in an open condition; vii) the carton transfer shuttle 40 then moves to the trailing panel of the partially formed carton B1 or B2, the vacuum elements 47a, 47b thereof are energized to grip the panel and the end flap folding bracket 52 is deployed to fold the trailing end flap; viii) the vacuum elements 85a, 85b, 85c, 85d or 86a, 86b, 86c, 86d of the retriever shuttle 30 are then deactivated and the carton transfer shuttle 40 transfers the partially formed carton B1 or B2 from the retriever shuttle 30 to the flap folding and gluing assembly 5, is received between the conveyors 54 of the side folding stations 53, which are drawn toward one another to match the width of the carton, and the end flap folding bracket 52 is deployed to fold the leading end flap; ix) the vacuum elements 47a, 47b of the carton transfer shuttle 40 are then deactivated and the conveyors 54 convey the carton over the glue applicator 50b, which applies glue supplied from the glue station 50 via the feed tube 50a; x) as the carton reaches the end of the conveyors 54, the side folding stations 53 are deployed to fold the side flaps against the end flaps; xi) the carton is then transferred from the conveyors 54 of the side folding stations 53 to the side conveyors 60 of the conveyor assembly 6, which are drawn toward one another to match the width of the carton; and xii) the carton is conveyed to the centre of the conveyor 6, where it pauses while the compression plate 71 of the flap compression assembly 7 is lowered to compress the flaps of the carton, after which the compression plate 71 is raised and the finished open top carton is then conveyed out of the machine 1.

Following the retrieval of the carton blank B1 or B2, the stack of carton blanks B1 or B2 in the appropriate magazine assembly 2 is then advanced by the pusher feed assembly 22 and the jack assembly 25 is again operated such that the feet 27a raise the exposed carton blank B1 or B2, ready for a further cycle.

It will be appreciated that the configuration of the machine 1 enables both left handed carton blanks B1 and right handed carton blanks B2. Indeed, the provision of the rotary folding arms 39 on the trailing side of the retriever 3 enable each of the magazine assemblies 2 to accommodate left handed blanks B1 or right handed blanks B2, since the rotary folding arms 39 can be used to open carton blanks B1 or B2 of the opposite configuration shown and described. Indeed, it is expressly envisaged that each of the rotary folding arms 39 may be replaced with a case breaker guide plate 87, in which case their position may be adjustable to accommodate the requisite carton blank size and/or configuration. Alternatively, each of the case breaker guide plates 87 may be replaced by a rotary folding arm 39. Alternatively, the case breaker guide plates 87 may be positioned on the trailing side of the retriever 3 and the rotary arms 39 may be positioned on the leading side of the retriever 3.

Turning now to Figure 11, there is shown a carton forming machine 100 according to another embodiment similar to the first embodiment, wherein like references depict like features that will not be described further herein. The machine 100 according to this embodiment differs from the machine 1 according to the first embodiment in that it includes two pairs of opposed magazines 2 spaced from the first pair of opposed magazines 2 along the conveying direction and in that the retriever assembly 3 and the carton transfer assembly 4 are both mounted to a platform 101 mounted to a pair of rails 102 and movable therealong in the conveying direction.

It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention, some of which are mentioned herein, while other variations would be readily apparent to the skilled person from the disclosure herein. It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.

Claims

1. A carton forming machine comprising at least two magazines for receiving respective carton blank stacks each for making a different carton variant, a retriever for selectively retrieving a carton blank from one of the magazines, carton forming means for forming a carton blank retrieved by the retriever and a controller for receiving a plurality of carton variant requests, wherein the controller is configured on receipt of each request to cause the retriever to retrieve one carton blank corresponding to the requested carton variant and to cause the carton forming means to form a carton therefrom.

2. Machine according to claim 1, wherein the magazines comprise at least one pair of opposed magazines between which the retriever is movable to selectively retrieve carton blanks therefrom.

3. Machine according to claim 2, wherein the retriever comprises a shuttle with a gripper on each of its magazine-facing sides for gripping a carton blank from a facing magazine.

4. Machine according to any preceding claim comprising a carton opening means associated with each magazine for retaining part of an exposed carton blank such that on retrieval thereof, in use, by the retriever, the carton blank is opened by movement of the retriever toward the other magazine.

5. Machine according to claim 4 when dependent upon claim 3, wherein each of the retriever and the opening means comprises a suction device for gripping opposite sides of an exposed carton blank.

6. Machine according to any preceding claim comprising a carton blank raising means associated with each magazine and configured to raise, in use, an exposed carton blank prior to its retrieval by the retriever thereby to separate it from one or more other carton blanks in the stack.

7. Machine according to claim 6 when dependent upon claim 5, wherein the suction device of the opening means is configured to grip, in use, an upper, exposed portion of the raised blank on the opposite side thereof to the retriever.

8. Machine according to claim 6 or claim 7, wherein the carton blank raising means comprises a pusher for pushing the bottom of an exposed carton blank upwardly.

9. Machine according to claim 8, wherein the pusher comprises a jack with a lifting foot projecting therefrom for engaging a lower edge of an exposed carton blank.

10. Machine according to claim 9, wherein the jack comprises a stop against which the exposed carton blank may abut for aligning the lower edge thereof with the foot prior to lifting.

11. Machine according to claim 10, wherein the lifting foot is adjustable with respect to the stop for accommodating different carton blank thicknesses.

12. Machine according to any one of claims 8 to 11, wherein the carton blank raising means comprises an abutment for inhibiting upward movement of one or more carton blanks adjacent the exposed carton blank whilst allowing upward movement of the exposed carton blank.

13. Machine according to claim 4 or any one of claims 5 to 12 when dependent upon claim 4, wherein the carton opening means comprises an angled or curved guide plate against which an end panel of the carton blank is urged, in use, as the retriever is moved toward the other magazine.

14. Machine according to claim 4 or any one of claims 5 to 13 when dependent upon claim 4, wherein the carton opening means comprises a deployable arm which is movable, in use, between a retracted position and a deployed position in which the arm is urged against an end panel of the carton blank thereby to open the carton blank.

15. Machine according to any preceding claim, wherein each magazine is movable vertically to adjust the position of a carton blank stack received thereby relative to the retriever and/or horizontally to accommodate carton blanks of different widths.

16. Machine according to any preceding claim comprising a conveyor for conveying a partially formed carton blank along a conveying direction, wherein the magazines are configured to receive carton blanks with their major surfaces parallel to the conveying direction.

17. Machine according to claim 16, wherein the carton forming means comprises a pair of end flap folders aligned with the conveyor, a first of the end flap folders being on a trailing side of the retriever and a second thereof being on the leading side of the retriever for folding, in use, end flaps of a carton retrieved by the retriever.

18. Machine according to claim 17 comprising a carton transfer shuttle movable along the conveying direction and including the first end flap folder and a gripper for gripping a partially formed carton blank from the retriever, folding the trailing end flap and transferring the partially formed carton blank to the conveyor.

19. Machine according to claim 17 or claim 18 comprising a carton closer beneath the conveyor and including the second end flap folder.

20. Machine according to claim 19, wherein the carton closer comprises a pair of side flap folders extending along at least part of the conveyor for folding, in use, side flaps of a carton conveyed along the conveyor.

21. Machine according to claim 19 or claim 20, wherein the carton closer comprises a glue or tape applicator for securing two or more of the flaps together.

22. A packaging system comprising a carton forming machine according to any preceding claim and a carton variant management means for generating and sending to the carton forming machine a request for a carton variant.

23. System according to claim 22 further comprising one or more loading stations each including one or more carton escrow bays for receiving a carton variant, wherein the carton variant management means comprises detection means for detecting a shortfall in one of the carton variants at the one or more loading stations and is configured to generate and send on detection of such a shortfall to the carton forming machine a request for that carton variant.

24. System according to claim 22, wherein the carton variant management means comprises an order management system configured to receive an order for a plurality of objects, to select based on the plurality of objects a carton variant and to generate and send to the carton forming machine a request for that carton variant.

25. System according to any one of claims 22 to 24 comprising a carton sizing machine having a controller, one or more cutters, one or more markers and measuring means configured to determine the footprint of an open top carton and the height of objects contained within the carton, the controller being configured to position, in use, the cutters based on the footprint, to cut vertical corner edges of the carton based on the height of the objects, to position the markers based on the footprint and height of the objects and to score or crease vertical walls of the carton between the vertical edges to define foldable panels.

26. A magazine assembly for use in a machine according to any one of claims 1 to 21 or a system according to any one of claims 22 to 25, the assembly comprising a cradle for receiving a stack of carton blanks and a carton blank raising means at or adjacent one of its ends and configured to raise, in use, an exposed carton blank prior to its retrieval by a retriever thereby to separate it from one or more other carton blanks in the stack.

27. A method of forming a carton using a carton forming machine having at least two magazines for receiving respective carton blank stacks each for making a different carton variant, the method comprising receiving a plurality of carton variant requests and, in response to each request, causing a retriever of the machine to retrieve one carton blank from one of the magazines which corresponds to the requested carton variant and causing a carton forming means of the machine to form a carton therefrom.

28. Method according to claim 27 comprising raising using a carton blank raising means the carton blank to be retrieved prior to its retrieval by the retriever thereby to separate it from one or more other carton blanks in the stack.

29. Method according to claim 28 comprising gripping using a suction device of the retriever a first side of the raised carton blank and gripping using a suction device of the magazine an upper, exposed portion of the raised blank on the opposite side thereof to the retriever and moving the retriever away from the magazine such that the carton blank is opened.

30. A computer program element comprising computer readable program code means for causing a processor to execute a procedure to implement one or more steps of the method of any one of claims 27 to 29

31. A yet further aspect of the invention provides the computer program element of claim 30 embodied on a computer readable medium.

32. A computer readable medium having a program stored thereon, where the program is arranged to make a computer execute a procedure to implement one or more steps of the method of any one of claims 27 to 29.

33. A control means or control system or controller comprising the computer program element of claim 30 or claim 31 or the computer readable medium of claim 32.

34. A carton forming machine substantially as described herein and/or as shown in the accompanying drawings.

35. A packaging system substantially as described herein and/or as shown in the accompanying drawings.

36. A magazine assembly substantially as described herein and/or as shown in the accompanying drawings.

37. A method of forming a carton substantially as described herein and/or as shown in the accompanying drawings.