US20230339639A1

US20230339639A1 - Packaging device and process for articles to be packaged

Info

Publication number: US20230339639A1
Application number: US17/998,805
Authority: US
Inventors: Salvatore Carboni; Antonio Vitali
Original assignee: GD SpA
Current assignee: GD SpA
Priority date: 2020-07-09
Filing date: 2021-07-05
Publication date: 2023-10-26
Also published as: JP2023533117A; EP4178865A2; CA3183637A1; WO2022009066A2; CN115867488A; IT202000016678A1; WO2022009066A3

Abstract

A continuously operating device and process for packaging articles are presented, where the overall dimensions are contained despite use of a high number of robotic systems. The articles are fed on a first conveyor line. A second conveyor line is provided for flow of open box-shaped packagings to be filled with the articles arranged in layers. Transfer devices pick the articles and insert them in a respective target box-shaped packaging. Each transfer device includes a handling member and a gripping device, both movable along three orthogonal axes. A control unit for controlling the transfer devices includes a collection of laws of motion and/or relevant trajectories defining the motion of the transfer devices. A set of laws of motion and/or relevant trajectories is selected from the collection according to a predetermined number and size of the layers.

Description

The present invention relates to a device and a process for packaging articles to be packaged.
The present invention finds a preferred, though not exclusive, application in the field of canned packaging of loose articles, such as capsules for infusion products, for example coffee, a field to which reference may be made hereafter without loss of generality.
In particular, in the relevant technical field, packaging apparatuses are known where the articles to be packaged are arranged according to predefined configurations that allow them to be inserted inside box-shaped packagings in the most compact manner possible.
In this description as well as in the accompanying claims, certain terms and expressions are deemed to have, unless otherwise expressly indicated, the meaning expressed in the following definitions.
Here and hereafter, “article to be packaged” means an article intended to be packaged, in a certain number, in a container, such as box or, in general, packaging.
In particular, it is envisaged that, for this purpose, the articles to be packaged are provided on a conveyor line, which comprises at least two rows of articles to be packaged, according to a particular configuration. This configuration, referred to below as a pattern, is the repetitive pattern in which the articles to be packaged are positioned in said rows, and which is transferred to said packaging. An example of a predetermined pattern, by way of illustration, could be a checkerboard pattern.
The articles can be, for example, food and confectionery products already packaged in individual containers or wrappers, such as coffee capsules or other infusion drinks, bottles and cartons of beverages, yoghurt pots, individual chocolates (wrapped or bare), candies, small boxes, pouches containing solid, liquid or semi-solid food products; moreover, products of the ceramic industry, absorbent products for hygienic use, products of the tobacco industry, products of the cosmetic industry, products of the pharmaceutical industry, products of the personal & home care industry.
The articles may be identical to each other, or they can differ from each other for some characteristic of shape and/or appearance, such as the conformation, the composition, the colour or the orientation with respect to other articles to be packaged.
Again purely by way of example, an article to be packaged is represented by a capsule, i.e. a hollow element of round or cylindrical shape, having the function of a container, of wrapping, of casing, of protection, of covering or closing of a product contained within it, therefore possessing a predetermined shape, in which a head and a bottom are identified, which envisages that it is provided in an upright vertical arrangement, resting on its bottom on a transport plane defined by the respective conveying line, but which may possibly assume an upturned arrangement, always with respect to a vertical axis, resting on the head opposed to said bottom, where, on the conveying line, seats, such as recesses and/or supports, may be provided to maintain the element in the aforesaid arrangements, in particular where they do not have a bottom and/or a head suitable for acting as a stable support base on said transport plane.
One of these positions may be identified as a head-to-head upright arrangement, referred to as an upright arrangement for short, while the opposite position may be identified as a head-to-bottom upturned arrangement, referred to as an upturned arrangement for short.
It is understood that the use of two or more different arrangements may apply to any article to be packaged, in particular when the selected arrangements are intended to achieve an interlocking and/or a more compacted framing within a target packaging.
Inside the pattern, as defined above, the elements to be packaged constitute a compact assembly wherein the respective arrangements and/or types vary within that assembly, but they are equally repeated from assembly to assembly.
In case of capsules, they may be arranged in upright and upturned arrangements in the same predetermined pattern, or with capsules staggered and alternating with each other according to their respective upright or upturned arrangement.
It is understood that the articles to be packaged are continuously fed when they move at a predetermined speed, possibly variable, i.e. subject to acceleration and deceleration, but never nihil. Continuous feeding therefore differs from step feeding, in which the packaging articles move in a step-by-step motion.
“Packaging device operating continuously” and “continuous packaging process” mean a device and process in which the articles to be packaged and/or the respective box-shaped packagings are fed continuously on the respective conveyor lines.
By “gripping element” it is meant an element designed to grip, and thus to pick up, and release one or more articles to be packaged, preferably a single article to be packaged, to transfer it from one conveyor line to another conveyor line, and this other conveyor line may possibly transport packagings in which the articles to be packaged are inserted.
“Direct transfer path” means a path without intermediate stops, in which a quantity of articles to be packaged is transported from one conveyor line to a subsequent destination, for example a box-shaped packaging.
This means that, in the transfer path, the articles to be packaged remain integral with the respective gripping elements that picked them up.
A “transfer device” is a device designed to carry out a transfer of articles which are intended to be packaged from a conveyor line to a target box-shaped packaging. A transfer device comprises, for example, a handling member, such as an assembly of articulated arms, and a gripping device, preferably movable in space, i.e. at least capable of moving the gripping device along three orthogonal axes, (X, Y, Z), controlled by said handling member, with laws of motion and relevant trajectories that the gripping device and the articulated arms travel in space.
The “operational volume” of a transfer device means all the space that can be travelled by the handling member and the gripping device of the transfer device.
“Delta-type robotic system”, or parallel robotic system, means a robot consisting of three arms connected by universal joints to a base, wherein the arms are of the parallelogram type, which maintain the orientation of the gripping device at the end.
By “laws of motion and/or trajectories” it is meant the definition of the paths that the whole transfer device, i.e. the handling member and the gripping device, follows in the three-dimensional space, where “trajectory” means a curve or a set of curves followed in space, and “law of motion” means the definition of one or more paths followed as a function of time.
The “flow of box-shaped packagings” means the continuous feeding of box-shaped packagings or the like onto a respective conveyor line, where they are filled with articles to be packaged; in this respect the box-shaped packagings are fed in an open configuration, i.e. allowing the insertion of articles to be packaged.
“Layered arrangement” refers to the positioning of articles which are intended to be packaged, in the target packaging, on superimposed layers. In a layered arrangement, the use of a predetermined pattern of the articles to be packaged in each layer can result in a greater compactness of the articles to be packaged, and thus in the packaging of articles in smaller volumes.
“Correct placing” of a layer of articles intended to be packaged means a layer that comprises the intended number of articles to be packaged and occupies an intended position in the target packaging.
On the contrary, “incorrect placing” of a layer means the placing of a layer that does not comprise the intended number of articles to be packaged and/or does not occupy an intended position in the target packaging.
“Buffer” refers to a station where a quantity of articles which are intended to be packaged is placed to await a further transfer.
A “number” of elements or articles means a quantity of elements or articles that is greater than or equal to two.
The Applicant noted that, in packaging processes, the speed of transfer and insertion of the articles to be packaged into the target packagings is crucial to the overall economics of the process, as high production volumes can be achieved with fewer packaging apparatuses.
Furthermore, the Applicant observed that, in addition to the need to proceed as quickly as possible, another important and unavoidable requirement is the flexibility required of this type of plants, in particular with regard to the different packaging formats, which may contain, for example, a few articles on one or two layers, up to many articles, for example twenty-four (6x4) on a large number of layers, for example five.
This requirement is felt when in case of capsules, they have a substantially truncated conical or truncated pyramidal shape, or equivalent shapes, or other shapes that allow the upright and upturned capsules to be set together in a predetermined arrangement.
By way of example, single small-format packagings and single large-format packagings can be envisaged; a single small-format packaging might contain, for example, two layers each consisting of a single row of three or four capsule elements, or two layers each with 2x3 capsule elements.
On the other hand, a large-format box might contain three 4x5 layers, or four or five 4x6 or 5x6 layers, and it is essential not only that the same plant can ensure these different packagings, but that it can do so with the replacement of a minimum number of parts.
The Applicant also verified that a rapid filling of packagings fed in a continuous flow appears to be a somewhat promising solution, but this filling can be carried out by a plurality of transfer devices which are arranged along a line of predetermined length, acting as transfer devices for the box-shaped packagings.
The extent of this length cannot, in most cases of practical interest, be arbitrary, but must be subject to design limits aimed at keeping the packaging apparatus sufficiently compact.
In general, the transfer devices are generally made up of pick-and-place robotic systems.
It should be noted that robotic systems known as “collaborative robots” or “delta robots” or similar can also be employed.
However, the Applicant found that the use of these robotic systems, in which gripping devices pick up the articles to be packaged and insert them into the packagings proceeding along a continuous flow, requires the provision for each of them of its own operating space, so that the length of a succession of robotic systems is inevitably conditioned by the operating space that each robotic system occupies, taking into account all its possible movements.
Furthermore, the Applicant verified that such robotic systems are generally programmed to carry out the transfer of articles to be packaged from a departure location to an arrival location, while the control system of the single robotic system autonomously determines the law of motion and the most appropriate relevant trajectory to move its gripping device between the departure location and the arrival location, exploiting the entire width of the operating space provided to the robotic system at the time of its design.
The Applicant, moreover, understood that, to increase the compactness of a packaging apparatus, it is necessary to bring the transfer devices close to one another, even though there is a risk that the laws of motion may determine trajectories of the gripping elements that entail the risk of interference, which could have even catastrophic consequences on the functionality of the packaging apparatus.
The problem outlined here is common to any succession in line of robotic transfer and/or filling systems, each of which operates within a determined operating space, defined by all the possible trajectories that the respective control system could select in order to carry out the intended transfer and filling tasks.
The Applicant therefore perceived that the drawbacks mentioned with reference to the prior art can be obviated by preventing the respective control systems from choosing, for each robotic system employed, any one trajectory for moving the articles to be packaged from a departure position, for example defined on a conveyor line for the articles, to an arrival position, for example a box-shaped packaging in which the articles to be packaged are inserted and laid in layers.
The Applicant finally found that selecting a set of laws of motion and/or relevant trajectories for the gripping devices of each robotic system in such a manner that these trajectories do not involve any interference, allows the robotic systems of a line of transfer devices to be brought close to one another even at a spacing at which the respective operating spaces are partially superimposed, thereby achieving a more compact packaging apparatus.
In particular, in a first aspect thereof, the invention relates to a device for packaging articles.
Preferably, said articles are articles to be packaged and said packaging device is provided for an apparatus for packaging said articles.
Preferably, said packaging device is operating continuously.
Preferably, said packaging articles are fed on a first conveyor line.
Preferably, said packaging device comprises a second conveyor line.
Preferably, said second conveyor line is arranged in proximity of said first conveyor line.
Preferably, a flow of box-shaped packagings apt to be filled with said articles to be packaged is transported on said second conveyor line.
Preferably said box-shaped packagings are in an open configuration.
Preferably, said articles to be packaged are arranged in said layered box-shaped packagings of predetermined dimensions.
Preferably, the packaging device comprises a plurality of transfer devices for picking articles to be packaged from said first conveyor line.
Preferably, said transfer devices insert the articles to be packaged into a respective target box-shaped packaging.
Preferably, said transfer devices each comprise a handling member and a gripping device.
Preferably, said gripping device is controlled by said handling member.
Preferably, said handling member and gripping device are both movable along three orthogonal axes, (X, Y, Z).
Preferably, the packaging device comprises a control unit controlling the transfer devices.
Preferably, the control unit comprises a collection of laws of motion and/or relevant trajectories defining the movement of said transfer devices.
Preferably, a set of laws of motion and/or relevant trajectories is selected from said collection according to the number and the predetermined size of the layers of articles to be composed in said box-shaped packagings.
Thanks to these features, it is possible to realise a packaging device with a small overall size, while still using a large number of robotic systems as transfer devices.
In a first embodiment, this can be achieved by selecting the trajectories of the handling members and gripping devices of the single transfer devices in such a manner that they never intersect, even though the respective operating spaces of the robotic systems may be partially superimposed.
In a further embodiment, this can also be achieved if the trajectories of the handling members and gripping devices of the single transfer devices intersect. In this case, it will be sufficient to select the laws of motion of the single transfer devices in such a manner that they do not travel incidental trajectories in the same time intervals.
Therefore, thanks to these characteristics, with a greater compactness among the transfer devices, the respective handling member and gripping devices of the transfer devices, which move according to trajectories and/or laws of motion selected a priori according to the specific type of packaging device to be made, do not risk coming into contact with each other.
In a second aspect thereof, the invention relates to a process for packaging articles.
Preferably, said articles are articles to be packaged.
Preferably, said packaging process is a continuous packaging process.
Preferably, the articles to be packaged are fed on a first conveyor line.
Preferably, the articles to be packaged are intended to be packaged in a flow of respective box-shaped packagings.
Preferably each packaging is in an open configuration.
Preferably, this flow of box-shaped packagings is transported on a second conveyor line.
Preferably, said process comprises a step of picking articles to be packaged from said first conveyor line.
Preferably, the picking step is carried out by means of a plurality of transfer devices for picking articles to be packaged from said first conveyor line.
Preferably, said process comprises a step of transferring the articles to be packaged from said first conveyor line to said second conveyor line.
Preferably, said process comprises a step of forming layers of articles to be packaged in said box-shaped packagings by inserting the articles to be packaged, picked in the previous step, into a respective target box-shaped packaging.
Preferably, in the transfer step, said transfer devices move according to laws of motion and/or relevant trajectories which are selected from a collection of laws of motion and/or relevant trajectories.
Preferably, a set of laws of motion and/or relevant trajectories for said plurality of transfer devices is selected from said collection.
Preferably, this choice is made according to the predetermined dimensions and the number of layers provided in said box-shaped packagings.
In other words, once the type of box-shaped packaging to be filled, i.e. the number and shape of each layer to be superimposed in each box-shaped packaging fed into said flow, has been selected by means of a control system, a set of laws of motion and/or relevant trajectories for the transfer of the articles to be packaged is selected for all the transfer devices, so that during the movement the transfer devices never come into contact with each other, even if the operating space of the robotic system of each transfer device intersects the operating space of the robotic systems that are adjacent thereto.
In a third aspect thereof, the present invention relates to a packaging apparatus comprising a device for packaging articles according to the first aspect.
In other words, this apparatus comprises a device for packing articles to be packaged, in which the latter are transferred into a flow of box-shaped packagings by means of transfer devices that are made up of respective robotic systems.
In particular, these robotic systems are of the Delta type, or parallel robotic systems, i.e. a robot comprising arms, in particular three, connected by universal joints to a base, wherein the arms are of the parallelogram type, which maintain the orientation of the gripping device at the end.
In the packaging apparatus, the aforesaid robotic systems are aligned in proximity of and along said second conveyor line, and they are positioned close together in such a manner that the operational volume of the aforesaid robotic systems is partially superimposed between adjacent systems; however, the laws of motion and/or the relevant trajectories selected for the transfer of the articles to be packaged ensure that they never come into contact with each other.
In a fourth aspect thereof, the present invention relates to a control system for a packaging apparatus which provides for the execution of a packaging process in accordance with the second aspect of the invention.
In other words, the control system receives as input the format of the box-shaped packagings to be filled, in particular number and shape of each layer to be placed in it, and selects, from an appropriate collection of laws of motion and/or relevant trajectories, a set of laws of motion and/or relevant trajectories that prevent the transfer devices from coming into contact with each other in carrying out the assigned task.
In a fifth aspect thereof, the present invention relates to a process or unit for transferring articles from a first line to a second conveyor line.
Preferably, said first and/or said second conveyor line are operated continuously.
Preferably, the aforesaid transfer is carried out by a plurality of transfer devices, for picking articles from said first conveyor line and transferring them to said second conveyor line.
Preferably, said transfer devices each comprise a handling member and a gripping device, which is controlled by said handling member.
Preferably, said handling member and gripping devices are movable along a three-dimensional space.
Preferably, each gripping device moves in translation along three orthogonal axes (X, Y, Z).
Preferably, each transfer device has an operational volume in which the respective handling member and gripping device can move.
Preferably, the transfer devices are arranged in proximity of each other, so that their respective operational volumes intersect with each other.
Preferably, said transfer is controlled by a control unit.
Preferably, the control unit controls the transfer devices.
Preferably, the control unit comprises a collection of laws of motion and/or relevant trajectories defining the movement of said transfer devices.
Preferably, the control unit selects a set of laws of motion and/or relevant trajectories from said collection.
Preferably, said set of laws of motion and/or relevant trajectories is selected according to a task to be accomplished by said transfer.
Preferably, said set of laws of motion and/or relevant trajectories is selected in such a manner that said transfer devices do not come into contact while performing said task.
In at least one of the aforesaid aspects, the present invention may further comprise at least one of the following preferred features.
In a preferred embodiment of the present invention, each gripping device is apt to pick, from said first conveyor line, a single layer of predetermined dimensions of articles to be packaged, and to insert it, in a single solution, into the respective target box-shaped packaging.
Preferably, the packaging device comprises, for each transfer device, a set of interchangeable gripping devices for each transfer device.
Therefore, each gripping device is provided to form a different type of layer of predetermined dimensions.
In other words, according to the dimensions of the layer to be placed, the packaging device is provided with the gripping devices necessary to make the desired layer, picking it from a suitable set of gripping devices.
Preferably, said first conveyor line is operating continuously.
Preferably, the articles to be packaged are transported on said first conveyor line at a predetermined speed.
Preferably, the articles to be packaged are arranged according to a predetermined pattern.
Preferably, said second conveyor line is operating continuously.
Preferably, said second conveyor line operates at a predetermined speed.
Preferably, in the packaging device, said first and said second conveyor lines move in counter-current with respect to each other.
Preferably, each transfer device comprises a Delta-type robotic system.
Preferably, said transfer devices are positioned between said first line and said second line.
Preferably, said transfer devices are aligned one after the other.
Preferably, in the packaging device each gripping device comprises a plurality of gripping elements, each apt to pick a single article to be packaged.
Preferably, in the packaging device said first conveyor line comprises a number of single-row lines of articles to be packaged, arranged in an upright arrangement and upturned arrangement according to said predetermined pattern with articles to be packaged staggered and alternating with each other according to said arrangement.
Preferably, said predetermined pattern is a checkerboard pattern.
Preferably, in the packaging device said first conveyor line comprises a pair of rows of articles to be packaged.
In a preferred embodiment of the present invention, the packaging device comprises at least one image detecting device which is provided to detect the conformity of the layers deposited in the box-shaped packagings by the transfer devices.
Preferably, each one or more image detecting devices corresponds to at least one respective transfer device and positioned in proximity of the flow of box-shaped packagings; said one or more image detecting devices are provided to detect the conformity of the layers downstream of each transfer device with respect to said flow, and said control unit receives a signal, from the at least one image detecting device, for correct placing of the layers or an alarm signal for incorrect placing of the layers.
In one embodiment, a respective imaging device is provided for each transfer device.
Preferably, said one or more imaging devices are connected to said control unit, so that said control unit can receive a signal for correct placing of the layers or an alarm signal for incorrect placing of the layers.
In this way, the packaging device according to this embodiment is able to exclude incomplete incorrect packagings as soon as an incomplete layer or an incorrect placement of the articles is detected, without waiting for the end of the filling process of the box-shaped packagings.
In fact, in the prior art, the control of the correctness of the packaging is carried out by measuring the total weight of the box-shaped packaging after it has been filled, which is uniquely determined by knowing the number and weight of the articles to be packaged that a box-shaped packaging must contain.
If a box-shaped packaging has not been filled as envisaged, it is discarded, with subsequent recovery of the articles that can be fed back into the packaging device.
However, as well as requiring an additional station to weigh and possibly discard incomplete box-shaped packagings, this operation requires the articles to be recovered to be processed manually by an operator, which adds to costs.
Thanks to the aforesaid feature, however, in the packaging device of the present invention the non-conformity of the placement of a layer of articles can be detected immediately, thus avoiding continuing to fill the box-shaped packaging intended to be discarded.
Furthermore, thanks to the aforesaid characteristic, it is also possible to detect nonconformities due to an incorrect positioning of articles within a layer, for example if an article is placed at an angle, thus compromising the correct deposit of the next layer and/or the correct closure of the packaging. It will be noted that such an event of non-conformity would not be detected by a control of the final weight of the packaging, but would instead require a visual check by an operator.
The articles that would have been placed in the already incomplete packaging can be retrieved immediately, and reinserted into the packaging process.
In other words, the packaging device is capable of setting aside, for later reuse, packaging articles that would be intended for a packaging whose filling does not comply with the instructions given. The packagings in which an incorrect filling has been detected will be identified and discarded, while minimising the amount of packaging articles to be reinserted into the packaging apparatus.
Preferably, in this embodiment, the image detecting devices comprise a camera with a focal spacing corresponding to the spacing between its lens and the layer to be detected.
Preferably, the camera lens is positioned directly above the conveyor line of the box-shaped packagings, arranged at a predetermined spacing from the respective transport surface on which said box-shaped packagings are located.
Alternatively, each camera sends a digital image of the newly composed layer to the control unit, which compares it with an image of correct placements in a special collection: if no conformity is seen between the camera image and the expected image for a predetermined placement of a type and layer position, a non-conformity signal is output.
Any placements that have been programmed as incomplete can also be detected, so that a number of articles to be packaged that is not a multiple of the number of articles to be packaged that make up a single layer can be inserted in the box-shaped packaging.
Preferably, an embodiment of the packaging device according to the present invention comprises a plurality of buffers, arranged in the region of said first conveyor line.
Preferably, they are provided to receive articles to be packaged placed by said transfer devices.
Preferably, in such an embodiment, the transfer devices lay articles to be packaged in said buffers following said alarm signal for incorrect placing of the layers.
In addition, again in a preferred version of this embodiment, the buffers comprise support planes which are positioned close to the transfer devices, on which the articles are placed in a predetermined arrangement.
Preferably, said support planes have respective recesses to receive a single article each, identifying said predetermined arrangement.
Preferably, said control unit, by means of the transfer devices, provides for the removal of articles from said buffers for their transfer to subsequent target packagings.
It is specified that the movements of the transfer device from the first conveyor line to the buffer and from the buffer to the second conveyor line are also carried out following a law of motion and/or a trajectory envisaged in the set of laws of motion and/or relevant trajectories selected according to the number and dimensions of the layers of articles composing the box-shaped packagings, as explained above.
In other words, the selected set of laws of motion and/or trajectories comprises not only all the movements of each single transfer device between the first and the second conveyor lines but also all the movements of each single transfer device between the first and the second conveyor line and the respective buffers.
In an embodiment of the packaging process according to the present invention, it is comprised a step of calibrating the laws of motion and relevant trajectories, according to the number and mutual spacing of the transfer devices.
The calibration step comprises a check and possible adaptation of the selection and calculation of the speeds and trajectories that each transfer device must perform, verifying that its operation does not lead to undesirable drawbacks.
Preferably, the picking step comprises the forming, in a respective transfer device, a single layer of articles to be packaged of predetermined dimensions, before the respective transfer step.

The characteristics and advantages of the invention will become clearer from the detailed description of an embodiment illustrated, by way of non-limiting example, with reference to the appended drawings wherein:

• FIG. 1 shows a first perspective view of an embodiment of a packaging apparatus comprising a device for packaging articles according to the present invention;

• FIG. 2 shows a second perspective view of the packaging apparatus of FIG. 1 , from a different point of view to that of the previous figure to show the opposite side;

• FIG. 3 shows a plan view from above of the packaging apparatus in FIG. 1 ;

• FIG. 4 shows a first partial perspective view of the packaging apparatus in the previous figures;

• FIG. 5 shows a second partial perspective view of the packaging apparatus of the previous figures;

• FIG. 6 shows a third partial perspective view of the packaging apparatus of the preceding figures, which allows to visualize the device for packaging articles made according to the present invention;

• FIG. 7 shows an enlarged view of a detail of the packaging device in FIG. 6 ;

• FIG. 8 shows a side view of the device of FIG. 6 ;

• FIG. 9 shows an enlarged perspective view of a transfer device of the packaging device from FIG. 6 ;

• FIG. 10 shows a plan view from below of a first detail of the transfer device in FIG. 9 ;

• FIG. 11 shows a side perspective view of a second detail of the transfer device in FIG. 9 ;

• FIG. 12 shows an elevation view of an article to be packaged;

• FIG. 13 shows a side view illustrating the arrangement of the articles to be packaged in a box-shaped packaging; and

• FIG. 14 shows a view from above illustrating the arrangement of the articles to be packaged in the box-shaped packaging of FIG. 13 .

In the accompanying figures, 100 indicates as a whole an apparatus for packaging articles to be packaged 1, comprising a packaging device 400 made in accordance with the present invention, which in turn comprises a feeder device 300 operating on the head thereof.
The embodiment described below refers to articles to be packaged in a packaging, in particular a box-shaped packaging 30 in which articles that are different from each other, or the same but in different configurations, are arranged in a sorted manner on superimposed layers.
In this example, with reference to FIGS. 12 to 14 , a particular article to be packaged for non-limiting purposes, namely a capsule 1, is contemplated, such as a capsule for the production of drinks by infusion.
The capsule 1 is formed by a substantially rigid casing 2, which has a mouth 3 closed by a lid which, in the present example, is a laminar element that is adhered to the edges of this opening by gluing. The mouth 3 and the lid make a head 4 of the capsule 1, which is opposed to the bottom 5, which will be described below.
The lid 4 is applied to the casing 2 after the latter has been filled.
The casing 2, in the present example, may have a cup shape, i.e. a truncated cone shape having a bottom 5 at the smaller base thereof and inclined walls 6, with a slight flaring, and a top at which said mouth 3 is defined by a circular top edge 7 which has a protruding border 8 or shoulder on the top circumference.
Both the bottom 5 and the top lid 4 are substantially flat, so that the casing 2, i.e., the capsule, can assume a first upright bottom-to-head arrangement, in which the casing 2 rests on the bottom 5, and a second upturned head-to-bottom arrangement, in which the casing 2 rests on the lid 4, i.e., on the circular top edge 7 to which the lid 4 is applied.
Inside the box-shaped packaging 30, the articles to be packaged are arranged on superimposed layers 38, one of which is located at the bottom of the box-shaped packaging 30.
If the articles to be packaged are different from each other, in particular if they are of two different types, each layer will be formed in such a manner that the different articles are arranged according to a predetermined pattern.
On the other hand, if the articles to be packaged are identical but arranged in different arrangements, in particular in two different arrangements, each layer will be formed in such a manner that the articles in different arrangements are arranged according to a predetermined pattern (FIGS. 13 and 14 ).
In the example described herein, where the articles to be packaged are capsules 1 of the form described above, they will be arranged in the box-shaped packaging 30 in two different arrangements: the aforesaid upright arrangement and the aforesaid upturned arrangement.
In a preferred version of this example, the two configurations will be arranged in each layer 38 in a checkerboard pattern, wherein each element 1 in an upright configuration is flanked laterally by elements 1 in an upturned configuration, and vice versa.
In this way, each layer 38 may assume a compact configuration in which the inclined walls 6 of adjacent capsules 1 adhere (or are very close together) to each other. It is understood, however, that the checkerboard pattern is only one of the possible patterns, which may also include honeycomb patterns, or other patterns suitable for particular shapes of the articles to be packaged.
In a preferred version of this example, the capsules 1 of superimposed layers 38 in contact with each other are arranged, within the respective pattern, with the bottoms 5 of capsules 1 of different layers in contact with each other, and with the lids 4 of capsules 1 of different layers in contact with each other. For example, this can be achieved by alternating layers 38 with a checkerboard pattern, in which the superimposed capsules 1 in upright configuration and in upturned configuration are alternated from layer to adjacent layer.
In a preferred version of this example, referring in particular to capsules 1 having a circular top edge 7 with a protruding border 8 or shoulder on the top circumference, the capsules 1 of each layer 38 are arranged staggered from each other at a spacing substantially equal to the height of the protruding border 8. In this way, in a compact configuration such as that obtained with the superposition of layers with a checkerboard pattern as described above, the bottom 5 of the capsules 1 will rest on the protruding border 8 of the adjacent capsules, so as to obtain a more compact configuration.
The above described compact configurations allow a certain number of capsules to be allocated in smaller box-shaped packagings 30, with clear advantages in terms of less space occupied.
The packaging apparatus 100 provides for both forming the box-shaped packagings 30 and filling them with articles to be packaged, particularly but not exclusively the capsules 1 described above, to obtain a finished packaging intended to be packaged for shipment.
For this reason, the packaging apparatus 100 of the present embodiment is fed with stacks of blanks and with capsules 1, which are fed in an upright configuration at an inlet section 101.
More in detail, the apparatus 100 has a first forming line which is fed at a first inlet end thereof 102 with blanks by means of a feeding station 103; this first forming line assumes a U-shaped configuration by travelling along a curve on a rotating forming carousel 125, which comprises a plurality of forming devices 150.
The feeding station 103 performs the extraction of single blanks and is connected to a folding station 104 in which the blanks are arranged in a configuration in which they are sent on a blanks conveyor 105. In the folding station 104 the blanks undergo a preliminary folding of the panels and of the flaps that form the blank. In addition, they are correctly spaced apart from each other, also in view of their format, which may vary according to the box-shaped packaging 30 which is to be made.
The blanks conveyor 105 travels through a gluing station 106 in which a plurality of hot glue guns lay appropriate glue spots on appropriate flaps of the blanks. It feeds the forming devices 150 rotating on the forming carousel 125, so that each forming device 150 intersecting the final section of the blanks conveyor 105 receives a respective blank in the correct position and already provided with the necessary glue spots.
In the curved section of the forming line, the forming devices 150 form respective box-shaped packagings 30 by means of folding operations of the panels forming the blank, adhering the flaps provided with glue to some of the panels thereof in an appropriate manner.
As will be explained in more detail below, the packaging device 400 is provided to pick and pack articles, to be packaged, fed on a first conveyor line 115, as will be explained in greater detail below.
The packaging device 400, for the purpose of packing them, inserts and lays the articles which are intended to be packaged which are conveyed onto a second conveyor line 107, also operating continuously at a predetermined speed, which is arranged in proximity to said first conveyor line 115.
On the second conveying line 107, a flow of box-shaped packagings is transported in an open configuration, apt to be filled with said articles to be packaged in layers having predetermined dimensions.
In this embodiment, the two conveyor lines 107, 115 are arranged one next to the other, developed along essentially parallel straight lines, and operating in counter-current.
As anticipated above, the packaging apparatus 100 has a second inlet section 101 at which the capsules 1 are fed in an upright configuration in a substantially unsorted manner.
At the inlet section 101, the feeder device for articles to be packaged 300 comprises an inlet line 121 which, in this example, is formed by two inlet rows 121 a and 121 b (FIGS. 4 and 6 ).
The inlet line 121 is connected to a forwarding station 112, wherein the capsules 1 are arranged on said rows 121 a, 121 b, and wherein a start equipment regulates the passage of the capsules 1 based on feedback that takes into account the operating state of the devices of the following stations.
The feeder device 300 comprises an upturning equipment 301 and a spacer equipment 302, so that after the forwarding station 112 the capsules 1 are spaced apart from each other, and the capsules of one of the rows 121 a, 121 b of the inlet line 121 are upturned, so that the capsules 1 in that row are in an upturned arrangement.
Therefore, the feeder device 300 comprises a conveying line 113 having two rows 113 a, 113 b of capsules 1, one next to the other, of which one conveys capsules 1 in upright arrangement and the other conveys capsules 1 in upturned arrangement.
The rows 113 a, 113 b of the first conveying line 113 flank a transfer station 114, wherein the capsules 1 are transferred from the first conveying line 113 to respective rows 115 a, 115 b of the first conveyor line 115, wherein the arrangements of single capsules 1 are arranged according to a predetermined pick-up pattern.
Between the conveying line 113 and the first conveyor line 115 there are provided, in the transfer station 114 of the feeder device 300, a pair of first transfer devices 251 a, 251 b realized by respective Delta-type robotic systems, which are arranged in succession, and supported by the cage frame 109 above.
Each first transfer device 251 a, 251 b comprises a first handling member having a first assembly of three articulated support arms 126, which performs the function of a self-moving transfer arm.
They are provided to transfer a number of capsules 1 from a single row of the conveying line 113, which will then be either all in upright arrangement or all in upturned arrangement. Each transfer device has a respective gripping device 127 with a plurality of gripping elements 128 to each grip a single capsule 1 in any arrangement.
During the transfer, the gripping elements 128 move by staggering the capsules 1 that have been picked up from each other, so that they can be arranged on the first conveyor line 115 in a position compatible with the pick-up pattern, which the first transfer devices compose during their operation.
It should be noted that, in this transfer process, the capsules 1 are transferred with a direct transfer path, in which the capsules picked up from the conveying line 113 are at least partially staggered to each other during their path and, without intermediate stops, are laid on the first conveyor line 115 according to a predetermined pattern.
The number of rows 121 a, 121 b of the inlet line 121 coincides with the number of the rows 113 a, 113 b of the conveying line 113 and the number of rows 115 a, 115 b of the first conveyor line 115, i.e. two.
The transfer between the two lines 107, 115 is carried out by a succession of second transfer devices 200, realized by parallel robotic systems, in particular of the Delta type, which comprise a handling member, in particular a second assembly of three articulated arms 201, and a second gripping device 202 which is controlled by said handling member, movable along three orthogonal axes, (X, Y, Z).
The second robotic transfer devices 200 are supported by the cage frame 109 above.
The possible movements of the handling member and the second gripping device 202 define, for each second transfer device, an operational volume V, shown in FIG. 7 . For reasons of compactness, the second transfer devices 200 are arranged aligned on an intermediate straight line between the developments of the conveyor lines 107, 115, i.e. in proximity of at least said second conveyor line 107, in a close position, i.e. such that the respective operational volumes V are partially intersecting.
This type of robot generally has a self-learning system for working trajectories, and it is envisaged that it calculates trajectories such as not to collide with the robots at its side. However, this self-learning system may not be compatible with the required transfer rates.
For this reason, a control unit 500 of the packaging apparatus 100 controls the first transfer devices 251 a, 251 b and the second transfer devices 200 and, in this regard, it comprises a collection of laws of motion and relevant trajectories that determine the motion of the second transfer devices 200.
The laws of motion and the relevant trajectories are selected from a special collection so that the movements of the second transfer devices 202 do not intersect with each other, with potentially catastrophic effects, even if the operational volumes of each second transfer device 200 intersect with those of adjacent second transfer devices.
Since the movements of the second gripping devices 202 increase in both speed and complexity as the number of capsules 1 to be packaged increases for each box-shaped packaging 30, the laws of motion and the relevant trajectories are selected according to the number of layers and their predetermined dimensions at the input step in a control system that manages the packaging process in the packaging apparatus 100.
What is described herein for the second packaging devices 400 may also apply to the first transfer devices 251 a, 251 b, if requirements of greater compactness require that they are arranged with their respective operational volumes partially intersecting.
In order to verify that the chosen trajectories are compatible with the position of the transfer devices, a calibration step of the laws of motion and their trajectories can be provided, according to the number and mutual spacing of the transfer devices.
For example, it is possible to establish a set of laws of motion and/or trajectories for the first of the second transfer devices 200 following the path of the articles to be packaged for each task to be performed by the transfer device.
According to these first laws of motion and/or trajectories, those of the second of the transfer devices 200 will be calculated, followed by those of the third, fourth and so on.
At the end it will be possible to check that the trajectories and movement speeds of the transfer devices are carried out with inconvenience.
Each second gripping device 200 is apt to pick, from said first conveyor line 115, an entire single layer of predetermined dimensions of articles to be packaged by forming on it said predetermined pattern.
Since the layer may have a width greater than that of the two rows 115 a, 115 b of the first conveyor line, each second gripping device 202 may make multiple removals from the first conveyor line 115, forming for example a layer of 3x4 format, which requires two consecutive removals, or a 4x6 layer, which also requires two removals from a longer section of the first conveyor line 115.
The removals therefore precede the transfer step and the insertion step in the capsules 1, so that the insertion of a single layer 38 into a target box-shaped packaging 30 is done in a single solution.
In order to be able to manage a quantity of layers of different sizes, the second packaging device 400 comprises, for each second transfer device 200, a set of interchangeable gripping devices 202, so that each gripping device in the set is provided for the entire range of layers that the second packaging device 400 can handle.
The gripping device 202 comprises a plurality of gripping elements 203, each apt to remove a single capsule 1, which are supported by a respective support 204 protruding from a body 205 of the second gripping device 202.
In order to achieve the greatest possible compactness, the gripping elements 203 may be brought close to one another and staggered to each other by a drive equipment 206 contained in said body 205.
It should be noted that, in this embodiment, the gripping elements 203 are of two types: a first type 203′ which is provided to grip the head 4 of the capsule 1, and a second type 203″ which is provided to grip the bottom of the capsule 1 (FIG. 11 ).
Approaching and staggering the capsules 1 of each layer 38 grasped by the second gripping device 202 allows the insertion of the layer into a smaller box-shaped packaging 30.
In this embodiment, for each second transfer device 200, the packaging device 400 comprises an image detecting device 210, in particular a digital camera, connected to the control unit. However, it is understood that the packaging device 400 could have a number of cameras lower than the number of the second transfer devices 200, but a camera can be enslaved to more than a second transfer device 200.
In this example, the image detecting device 210 is positioned downstream of each transfer device 200 relative to the second conveyor line 107, to detect, after insertion, the conformity of the layers 38 deposited in the box-shaped packagings of the flow associated with the second conveyor line 107.
In the present example, the camera operates with a focal spacing corresponding to the spacing between its lens and the layer to be detected, so as to distinguish the presence or absence of the layer.
The camera is positioned by a fixed support 211 directly above the second conveyor line 107 of the box-shaped packagings 30, at a predetermined spacing from the respective transport surface on which said box-shaped packagings 30 is located in support.
Alternatively, each camera can send a digital image of the newly composed layer to the control unit, which compares it with an image of correct placements in a special collection: if no conformity is seen between the camera image and the expected image for a predetermined placement of a type and layer position, a non-conformity signal is output.
Therefore, in all of these variants the image detecting device 210 further comprises an image processing unit capable of analysing the images detected by the camera and comparing them with a control image, corresponding to a correct arrangement of the layer, in order to detect any discrepancies. The image processing unit is then able to output a signal for correct placing of the layer, or an alarm signal for incorrect placing of the layer, and to transmit this signal to the control unit. It should be noted that the image processing unit can be physically positioned either at the camera or at the control unit.
The packaging device 400 comprises a plurality of buffers 116, arranged in the region said first conveyor line 115, apt to receive capsules 1 therein deposited by the second transfer devices 200 in case it is impossible to insert them in the target packaging.
In particular, in combination with said image detecting devices 210 and signals provided to the control unit, the second transfer devices 200 lay the capsules subsequent to a signal of incorrect formation of a previous layer, so that the capsules are not laid in a packaging intended to be discarded.
The buffers 116 comprise support planes which are positioned close to the second transfer devices 200, on which the capsules are positioned in a predetermined arrangement.
In this respect, the support planes have respective recesses to receive a single capsule each, thus identifying said predetermined arrangement.
The control unit, by means of the second transfer devices 200, can in due course provide for the removal of the capsules 1 from said buffers 116 for their transfer to subsequent target packagings. On this occasion, forwarding station 112 will interrupt the flow of capsules 1 on the inlet line 121.
If, following a major malfunction, the space in said buffers 116 is exhausted, recovery tanks 117 are present alongside the buffers 116, apt to receive excess capsules from the second transfer devices 200.
It is understood that containers, for which a lack of conformity with the instructions in relation to the deposit of the capsules, in particular of the layers of capsules transferred by the aforesaid transfer devices 200, has been detected, whether the container has nevertheless completed its filling or whether the container is still missing layers, the capsules of which are deposited in the buffers 116, this container, at the end of its conveyor line 107, is discarded by a diverter equipment which may be of a substantially conventional type.
The discarded material will then be recovered, if possible, and reintroduced to the packaging cycle.
Once the filling is complete, the filled box-shaped packagings 30 arrive at a closing station 110. Subsequently, the closed box-shaped packagings 30 reach a discharge end 111, from where they are sent to a packaging apparatus.
To the above-described packaging apparatus and device and process for packaging articles to be packaged, a person skilled in the art may, in order to meet additional and contingent requirements, make numerous further modifications and variations, all of which are, however, within the scope of protection of the present invention as defined by the appended claims.

Claims

1-17. (canceled)

18. A continuously operating packaging device for articles to be packaged fed on a first conveyor line, said packaging device comprising:

a second conveyor line placed in proximity of said first conveyor line, said second conveyor line being configured to convey a flow of box-shaped packagings in an open configuration, said box-shaped packagings configured to be filled with said articles in layers of articles having predetermined dimensions;

transfer devices for picking the articles from said first conveyor line and inserting the articles in a respective target box-shaped packaging, each transfer device comprising a handling member and a gripping device controlled by said handling member, both being movable along three orthogonal axes; and

a control unit for controlling the transfer devices, comprising a collection of laws of motion and/or relevant trajectories defining movement of said transfer devices, wherein a set of laws of motion and/or relevant trajectories is selected from said collection according to number and predetermined size of the layers of articles configured to be grouped in said box-shaped packagings.

19. The packaging device according to claim 18, wherein said transfer devices comprise respective robotic systems having parallelogram arms connected by universal joints to a base, the parallelogram arms being configured to maintain orientation of the gripping device at their end, the robotic systems being aligned in proximity of and along said second conveyor line, and being positioned such that an operational volume of the robotic systems is partially superimposed between adjacent systems.

20. The packaging device according to claim 19, wherein said first and said second conveyor lines each operate continuously, and in counter-current with respect to each other.

21. The packaging device according to claim 18, wherein each gripping device is configured to pick, from said first conveyor line, a single layer of predetermined dimensions of articles to be packaged, and to insert the single layer, in a single solution, into the respective target box-shaped packaging.

22. The packaging device according to claim 21, comprising a set of interchangeable gripping devices for each transfer device, each gripping device of the set forming a different layer of predetermined dimensions.

23. The packaging device according to claim 18, comprising one or more image detecting devices, each corresponding to at least one respective transfer device (200), and positioned near the flow of box-shaped packagings,

said one or more image detecting devices being configured to detect conformity of the layers downstream of each transfer device with respect to said flow,

said control unit being configured to receive (i) a signal, from the one or more image detecting devices, for correct placing of the layers, or (ii) an alarm signal for incorrect placing of the layers.

24. The packaging device according to claim 18, further comprising buffers arranged at said first conveyor line and configured to receive articles placed by said transfer devices.

25. The packaging device according to claim 23, further comprising buffers arranged at said first conveyor line and configured to receive articles placed by said transfer devices, wherein the transfer devices are configured to place the articles in said buffers following said alarm signal for incorrect placing.

26. The packaging device according to claim 24, wherein said control unit, via the transfer devices, provides for the picking of the articles from said buffers to transfer the articles to subsequent box-shaped packagings.

27. A continuous packaging process for articles to be packaged fed on a first conveyor line, in a flow of respective box-shaped packagings in an open configuration conveyed on a second conveyor line, said process comprising:

a picking step of picking the articles from said first conveyor line, performed by transfer devices;

a transfer step of transferring the articles from said first conveyor line to said second conveyor line; and

a forming step of forming layers of articles in said box-shaped packagings by inserting picked articles into a respective box-shaped packaging,

wherein, in the transfer step, said transfer devices move according to laws of motion and/or relevant trajectories selected from a collection of laws of motion and relevant trajectories, wherein a set of movement laws and/or relevant trajectories for said transfer devices is selected from said collection according to a predetermined size and a number of layers placed in said box-shaped packagings.

28. The packaging process according to claim 27, wherein the picking step comprises forming, in a respective transfer device, a single layer of said articles, having a predetermined size, before a respective transfer step.

29. The packaging process according to claim 27, wherein said first and said second conveyor lines operate continuously and in counter-current with respect to each other.

30. The packaging process according to claim 27, further comprising:

a detecting step of detecting images of the layers formed in said forming step and,

in case of incorrect formation of the layers of the articles previously inserted in a box-shaped packaging, an emission step of emitting a non-conformity signal for the already inserted layers.

31. The packaging process according to claim 30, further comprising, in case of emission of the non-conformity signal,

a placing step of placing the articles, following the picking step, in buffers provided at said first conveyor line.

32. The packaging process according to claim 31, further comprising:

an additional picking step of picking the articles from said buffers,

an additional transfer step of transferring the articles from said buffers to said second conveyor line, and

a complementary step of forming layers of said articles in said box-shaped packagings by inserting picked articles in a respective target box-shaped packaging.

33. A packaging apparatus comprising the device according to claim 18.