WO2014118631A1 - Procédé et système de mise en forme automatique de boîtes d'emballage - Google Patents

Procédé et système de mise en forme automatique de boîtes d'emballage Download PDF

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Publication number
WO2014118631A1
WO2014118631A1 PCT/IB2014/000342 IB2014000342W WO2014118631A1 WO 2014118631 A1 WO2014118631 A1 WO 2014118631A1 IB 2014000342 W IB2014000342 W IB 2014000342W WO 2014118631 A1 WO2014118631 A1 WO 2014118631A1
Authority
WO
WIPO (PCT)
Prior art keywords
folding
blank
folding units
bottom panel
panel
Prior art date
Application number
PCT/IB2014/000342
Other languages
English (en)
Inventor
Herman Sytema
Franciscus Hermannus FEIJEN
Original Assignee
Neopost Technologies
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from PCT/EP2013/051698 external-priority patent/WO2014117818A1/fr
Application filed by Neopost Technologies filed Critical Neopost Technologies
Publication of WO2014118631A1 publication Critical patent/WO2014118631A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B7/00—Closing containers or receptacles after filling
    • B65B7/16—Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons
    • B65B7/26—Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons by closing hinged lids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
    • B31B50/14—Cutting, e.g. perforating, punching, slitting or trimming
    • B31B50/16—Cutting webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B5/00—Packaging individual articles in containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, jars
    • B65B5/02—Machines characterised by incorporation of means for making the containers or receptacles
    • B65B5/024—Machines characterised by incorporation of means for making the containers or receptacles for making containers from preformed blanks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/42—Details of containers or of foldable or erectable container blanks
    • B65D5/64—Lids
    • B65D5/66—Hinged lids
    • B65D5/6626—Hinged lids formed by folding extensions of a side panel of a container body formed by erecting a "cross-like" blank
    • B65D5/665—Hinged lids formed by folding extensions of a side panel of a container body formed by erecting a "cross-like" blank the lid being held in closed position by self-locking integral flaps or tabs
    • B65D5/6661—Flaps provided over the total length of the lid edge opposite to the hinge
    • B65D5/6664—Flaps provided over the total length of the lid edge opposite to the hinge combined with flaps or tabs provided at the side edges of the lid
    • B65D5/6667—Flaps provided over the total length of the lid edge opposite to the hinge combined with flaps or tabs provided at the side edges of the lid and connected to one another in order to form an uninterrupted telescoping flange
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B2100/00—Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs
    • B31B2100/002—Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs characterised by the shape of the blank from which they are formed
    • B31B2100/0024—Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs characterised by the shape of the blank from which they are formed having all side walls attached to the bottom
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
    • B31B50/25—Surface scoring
    • B31B50/256—Surface scoring using tools mounted on a drum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
    • B31B50/26—Folding sheets, blanks or webs
    • B31B50/52—Folding sheets, blanks or webs by reciprocating or oscillating members, e.g. fingers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B2210/00—Specific aspects of the packaging machine
    • B65B2210/04—Customised on demand packaging by determining a specific characteristic, e.g. shape or height, of articles or material to be packaged and selecting, creating or adapting a packaging accordingly, e.g. making a carton starting from web material

Definitions

  • the invention relates to a method and a system for automatically forming packaging boxes.
  • US-B1 -6, 170,231 discloses a method relating to wrap-around packaging, wherein discrete articles, such as books, are deposited upon carton blanks which are wrapped about the articles to surround all sides of the articles.
  • Articles of different sizes such as different pack sizes of books, are wrapped with a carton formed from a blank in a continuous manner in which a standard size blank is custom trimmed to a size related to the pack size and wherein slotting and scoring means are adjusted to form the blank so that it wraps neatly about the book packs.
  • Information on sizing from previous orders of book packs is stored and used by a controller to produce a pre-sized and pre- formed flat blank which is identical to the said previous orders.
  • the book packs are seated on a bottom panel of the flat customized blank, and the book packs and the blank are pushed downward forcing the carton blank through former guides to turn up end and side flaps.
  • the book packs and the partially erected box are fed horizontally to a former station where a top panel is bent over the book packs and the wrap-around packaging is finally finished by e.g. wrapping tape around the carton.
  • the controller operates automatically it is the operator of the apparatus who identifies the pack size for the books and thus the operation of the apparatus is prone to human error.
  • the object are achieved in accordance with the invention by providing a method for automatically forming packaging boxes, said method comprising the steps of: providing a blank having a rectangular bottom panel and rectangular side and end panels and a rectangular top panel;
  • top panel folder at a top folder level above the level defined by the bottom panel
  • the method further comprises the steps of:
  • the at least four folding units comprise a front pair of folding units and a rear pair of folding units positioned at a longitudinal distance from the front pair of folding units, wherein the folding units of the front pair are positioned at a transverse distance from each other, and wherein the folding units of the rear pair are positioned at a transverse distance from each other;
  • At least one of the at least four folding units is provided with a controllable gripping element for gripping the bottom panel, wherein said controllable gripping element is activated into an operative mode gripping the bottom panel and is deactivated for releasing the bottom panel;
  • the method comprises the step of packaging at least one article in a packaging box, preferably simultaneously with the formation of said packaging box, wherein the method further comprising the steps of:
  • said at least one article having overall length, width and height dimensions; by means of a feeding conveyor feeding blank material in a feeding direction, preferably along a feeding path free from corners or angles, from a storage of blank material to a blank forming station comprising a blank forming apparatus for cutting and creasing blank material into a custom sized blank and by means of said blank forming apparatus cutting and creasing blank material into a custom sized blank having a rectangular bottom panel and rectangular side and end panels based on the length, width and height dimensions;
  • sealing the packaging box at the sealing station preferably by means of a seal applicator apparatus of the sealing station;
  • the method comprises the step of adjusting the longitudinal distance and/or the transverse distances based on the length and width dimensions, respectively.
  • the top folding units can be provided with a gripping element e.g. for gripping the top panel.
  • the method comprises the step of providing an input conveyor comprising a number of input sub-conveyors positioned consecutively in conveying direction.
  • the method comprises the step of driving each of the input sub- conveyors independently of one another.
  • the operation of the method according to the invention can be checked when the method comprises the step of determining the number of articles present on at least one of the input sub-conveyors.
  • the method comprises the step of determining at which of the input sub-conveyors the at least one article is present during any given moment during conveying. In this manner it is possible to keep track of the progress of the articles during the operation of forming packaging boxes around the articles and by comparing the number of articles as determined to be present on a specific input sub-conveyor at a given moment with the expected number and position of articles it is possible to check whether the progress takes place correctly.
  • the method then comprises the step providing an alarm signal in case the number of articles determined to be present on said specific input sub-conveyor differs from the number of said at least one article which is expected to be present thereon.
  • an alarm signal can be used to automatically solve the detected discrepancy or can be used to notify a human operator that an inspection is necessary.
  • a transfer strip is provided adjacent to the downstream end of the input conveyor or the last input sub-conveyor. It is then preferred when the method comprises the step of stopping the conveying of said at least one article by means of the last downstream input sub- conveyor. Temporarily stopping the conveyance of the articles can in some cases be necessary to properly time the conveyance of the articles with the feeding of the custom sized blank, so that a correct positioning of the articles on the bottom panel can be obtained.
  • a step of measuring the overall length, width and height dimensions of said at least one article by a measuring device is included, in which preferably the step of measuring the length, width and height dimensions of said at least one article by means of said measuring device is performed during conveying of said at least one article by the input conveyor.
  • the overall dimensions can be provided via automatic identification of the article(s) through for example barcode scanning, RFID detection, image recognition and/or looking up the dimensions in databases or even by operator input, e.g. when handling many small batches of equally sized articles.
  • the step of cutting and creasing blank material into a custom sized blank having a bottom panel based on the dimensions is performed during feeding of said blank material in feeding direction. In this manner the time needed to automatically form closed packaging boxes can be decreased leading to a larger operating capacity.
  • the conveying direction of said at least one article is at least substantially parallel to the feeding direction of the blank material at the moment the at least one article is conveyed in horizontal direction onto the bottom panel supported by the folding units.
  • the method then comprises the step of providing the blank forming apparatus in a position below the input conveyor. In this manner an apparatus for performing the inventive method can be constructed in a relatively simple manner.
  • the step of feeding the bottom panel into the supporting station comprises feeding the blank material upwards via a (shallow) S-bend from the blank forming apparatus into the supporting station so that the conveying direction of the items and the feeding direction of the blank material at least substantially coincide at the level of the input conveyor.
  • Forming packaging boxes and packaging items therein can be performed in a relatively easy manner when the step of feeding the bottom panel into the supporting station is performed such that a center line of the bottom panel in conveying direction is centered between the folding units of the front and rear pair and/or when the step of conveying said at least one article from the input conveyor onto the bottom panel of the custom sized blank is performed such that a leading end of the at least one article positioned against the leading transverse folding line of the bottom panel.
  • the method comprises the step of activating the blank forming apparatus for cutting and creasing blank material into a custom sized blank when said at least one article is present on the last input sub-conveyor. It is then preferred to activate the blank forming apparatus only when the number of articles as determined to be present on the last input sub-conveyor equals the expected number of said at least one article, i.e. the number of articles belonging to the order to be processed. In addition it is possible to use the total weight or the identification of the articles (e.g. by scanning a (bar) code, RFID as a parameter for activating the blank forming apparatus.
  • the custom sized blank is formed at a stage in which it is almost certain that the correct articles to be packaged are present on the last downstream input sub-conveyor and it can thus be prevented that unintended changes in the number or position of articles necessitate that an earlier formed blank has to be discarded, not only leading to unnecessary waste of material but also leading to an unnecessary decrease of operating capacity.
  • the method comprises the step of providing the blank forming apparatus with a pair of longitudinal score line applicators for applying longitudinal score lines as folding lines to the blank material between respective panels, a single transverse score line applicator for applying transverse score lines as folding lines between respective panels, a single transverse cutter for cutting the blank material to the length of the custom size blank and a single longitudinal cutter or a pair of longitudinal cutters for cutting the blank material to the width of the custom sized blank, wherein the transverse distance between the pair of longitudinal score line applicators and/or the transverse distance between the longitudinal cutters is adjusted based on the width dimension.
  • the method comprises the step of moving the single transverse cutter along a line which is positioned at such an angle with respect to the feeding direction of the blank material, that in combination with a feeding speed of the blank material and a speed of said cutter along said line a cutting line transverse to the feeding direction, i.e. perpendicular to the side edges of the blank material, is formed in the blank material.
  • a cutter can be realized in the form of a displaceable rotating knife or a displaceable laser beam generator.
  • two or more transverse score line applicators can be used for applying transverse score lines.
  • the upstream blank material is retracted and/or the cutter is lifted to allow the reverse movement of the transverse cutter.
  • a custom sized blank is formed having a rectangular bottom panel having a center line (centrally positioned between longitudinal folding lines) substantially parallel to the feeding direction, rectangular side panels and rectangular end panels joined to the bottom panel, rectangular corner panels joined to the end panels, a rectangular top panel joined to one of the end panels, rectangular top side panels joined to the top panel, a rectangular top end panel joined to the top panel and rectangular top corner panels joined to the top end panel, having score lines between the rectangular bottom panel, the rectangular side panels, the rectangular end panels and the rectangular top panel and having cut-outs in line with respective score lines between the corner panels and the adjoining side panels provided by a cutting-out device of the blank forming apparatus.
  • a custom sized blank having such a constitution can be formed relatively simple and by a blank forming apparatus which is relatively simple of construction.
  • the operating capacity can be increased further when the method comprises the step of configuring the cutting-out device comprising a pair of opposite cut-out knives to displace the cut-out knives from an inactive position to an active position synchronously with a feeding speed of the blank material in feeding direction and even further when the method comprises the step of configuring the cutting-out device to displace the cut-out knives from the active position to the inactive position at a higher speed than the feeding speed of the blank material in a direction opposite the feeding direction. Since the cutting is performed during feeding of the blank material the inactive and active position are not stationary positions.
  • waste blank material is automatically discharged via a waste conveyor.
  • the waste can alternatively fall directly into a waste container.
  • said at least one article is positioned centrally on the input conveyor.
  • said blank material and said customized blank are positioned centrally on the feeding conveyor.
  • the step of positioning four folding units at a supporting station downstream of the conveyor in conveying direction relative to one another based on the dimensions comprises the step of adjusting the longitudinal distance and/or the transverse distances based on the length, width and height dimensions such that the four folding units of the front and rear pair are each positioned in a location in which they are able to support a respective corner of the rectangular bottom panel.
  • the folding elements on the folding units for folding side panels, end panels and corner panels can then be constructed in a relatively simple manner.
  • the folding units are displaced symmetrically with regard to a central line between the folding units, and preferably the adjustment of the transverse distances between the front folding units and the rear folding units is performed synchronously.
  • the device or apparatus for adjusting the relative distances between the folding units can be realized with a relatively simple construction.
  • the method comprises the step of activating the at least one gripping element into the operative mode before the step of folding side and end panels of said custom sized blank upwardly and the step of keeping the at least one gripping element in the operative mode at least until folding side and end panels of said custom sized blank upwardly has been completed.
  • the method comprises the step of, during gripping of the rectangular bottom panel, allowing the at least one gripping element to move freely in a horizontal plane in order to be able to follow possible transverse movements of the rectangular bottom panel.
  • the method comprises the step of providing the at least one gripping element with a suction cup for exerting underpressure at a respective gripping position at an underside of the rectangular bottom panel, said suction cup preferably being manufactured from flexible material.
  • the method comprises the step of raising the suction cup from a lower inoperative position to an operative position in contact with the bottom panel for gripping and supporting the bottom panel, wherein the underpressure in the suction cup preferably is activated before it contacts the bottom panel, such that the suction cup can reproducibly grip the bottom panel without changing the position of the bottom panel in the supporting station.
  • the step of adjusting the longitudinal distance between the rear and front folding units is performed during feeding of the custom sized blank into the supporting station, preferably by starting the displacement of the front pair of folding units towards the sealing station earlier than the displacement of the rear pair of folding units. Since adjusting of the longitudinal distance between the front and rear folding units takes place during displacement of the front folding units the time needed to fold a box can be reduced so that the process capacity can be increased.
  • the step of raising the suction cup is started during displacement of or preferably substantially simultaneously with starting displacement of the front pair of folding units towards the sealing station so that correct gripping can be realized and processing capacity can be increased.
  • the method comprises the step of displacing the folding units in a direction from the sealing station to the supporting station, wherein the step of adjusting the transverse distances between folding units is performed during said displacement of the folding units towards the supporting station.
  • the correct transverse position of the folding units to support a next custom sized bottom panel at the corners thereof can be assumed before the four folding units reach the supporting position thereby allowing increasing the operating capacity.
  • the transverse distances are first adjusted to a default transverse distance, e.g. in case the data for the transverse distance for the next custom sized bottom panel is not available yet and e.g.
  • Forming packaging boxes and packaging items therein can be performed relatively fast in an embodiment of a method according to the invention when the step of feeding the bottom panel onto the at least four folding units is performed without interruption after the step of cutting and creasing blank material into a custom sized blank.
  • the processing speed can be increased when the step of conveying the at least one article onto the bottom panel is performed while the custom sized blank is being fed onto the folding units.
  • the step of cutting and creasing blank material into a custom sized blank by said blank forming apparatus comprises the step of cutting and creasing blank material into a custom sized blank having a top panel downstream of the bottom panel and preferably at least one of top side panels, a top end panel and top corner panels
  • the method preferably comprises the step of, during transporting the custom sized blank from the supporting station towards the sealing station, gradually raising the top panel.
  • gradually raising the top panel is at the same time supported and thus prevented from inadvertently bending downwards.
  • gradually raising the top panel can promote further folding of the top panel.
  • the step of gradually raising the top panel is preferably performed by means of a top panel raiser, preferably comprising a slanting belt extending from the supporting station to the sealing station.
  • the method comprises the step of providing a top panel folder
  • the step of positioning the top panel folder at a top folder level above the level defined by the bottom panel based on the height dimension and the step of displacing the top panel folder in a direction from the sealing station towards the supporting station while the folding units are displaced from the supporting station towards the sealing station folding of the top panel into a position which is substantially parallel to the rectangular bottom panel can be performed reliably and quickly.
  • the method then comprises the step of providing the top panel folder with a top pair of top folding units, the step of adjusting a top transverse distance between the top folding units based on the width dimension, and the step of activating the top folding units for folding down top side panels and/or a top end panel and/or top corner panels preferably after the top panel has been folded into the position which is substantially parallel to the rectangular bottom panel.
  • a correct folding of top end, side and corner panels can be obtained in an embodiment of a method according to the invention when during activation of the top folding units the method comprises the step of reversing the displacement of the top panel folder so that the top panel folder is displaced in a direction towards the sealing station.
  • a further embodiment of a method according to the invention comprising the step of providing the top panel folder with at least one controllable rod, preferably at least two controllable rods, which after activating the top folding units is/are activated to engage a rear wall of the custom sized box, and preferably with at least one further controllable rod, preferably at least two controllable rods, which after activating the top folding units is activated to engage a (respective) side wall of the custom sized box recoiling of the top end panel and the top side panels can be prevented and in addition the rods engaging the rear wall of the box at least assist in further transport of the box towards the sealing station.
  • controllable rod(s) engaging the rear wall is (are) used for further transport towards the sealing station together with an additional supporting element extending centrally between the folding units and extending from the supporting station to the sealing station such that the folding units can be deactivated and already be returned to the supporting station after the rod(s) has (have) taken over transport.
  • a method according to the invention can be performed by a particularly compact and versatile apparatus when in a preferred embodiment of a method according to the invention the method comprises the step of providing each of the folding units of the front and rear pair and preferably the top pair with controllable end panel folding flaps and/or controllable side panel folding flaps and/or a controllable initiator for initiating the folding of a corner panel.
  • the method comprises the step of providing the seal applicator with displaceable seal applicator units and the step of displacing the seal applicator units based on the length, width and/or height dimensions. In this manner sealing boxes of different dimensions can be realized in a correct and automatic manner.
  • the invention further relates to a system for automatically forming packaging boxes, said system preferably being configured to execute the method according to any one of the preceding claims, said system comprising:
  • control unit for controlling the operation of the system
  • a blank forming apparatus operatively connected to the control unit for providing a blank having a rectangular bottom panel and rectangular side and end panels and a rectangular top panel;
  • folding units operatively connected to said control unit for folding side and end panels of the blank upwardly in a substantial vertical position and for gradually raising the top panel
  • a top panel folder operatively connected to said control unit and suspended for being positionabie at a top folder level above the level defined by the bottom panel and for being displaceable in a direction parallel to the rectangular bottom panel, wherein the control unit is configured for displacing the top panel folder in a direction parallel to the rectangular bottom panel for folding the top panel into a position in which it is positioned over and at least substantially parallel to the rectangular bottom panel.
  • Using a displaceable top panel folder the time needed to fold the top panel in order to form a packaging box can be shortened whereby the processing capacity can be increased.
  • the system further comprises: at least four folding units at a supporting station, each operatively connected to said control unit, wherein the at least four folding units comprise a front pair of folding units and a rear pair of folding units positioned at a longitudinal distance from the front pair of folding units, wherein the folding units of the front pair are positioned at a transverse distance from each other, and wherein the folding units of the rear pair are positioned at a transverse distance from each other; the folding units being configured for supporting a blank such that the folding units support the rectangular bottom panel;
  • At least one of the at least four folding units is provided with a controllable gripping element for gripping the bottom panel, wherein the control unit is configured for activating said controllable gripping element into an operative mode for gripping the bottom panel and for deactivating said controllable gripping element for releasing the bottom panel;
  • said at least one folding unit is configured for folding respective side and/or end panels of the blank upwardly.
  • the system is then incorporated in a system which is configured for packaging at least one article in a packaging box, preferably simultaneously with the formation of said packaging box, said system comprising:
  • an input conveyor for conveying, preferably horizontally conveying said at least one article in a conveying direction, said input conveyor being operatively connected to said control unit;
  • a feeding conveyor operatively connected to the control unit for feeding blank material in a feeding direction, preferably along a feeding path free from corners or angles, from the storage to the blank forming station;
  • said blank forming station comprising a blank forming apparatus operatively connected to said control unit for, under control of the control unit, cutting and creasing blank material into a custom sized blank having a rectangular bottom panel and rectangular side and end panels based on the data indicative for the length, width and height dimensions;
  • the supporting station being located downstream of the conveyor in conveying direction;
  • the at least four folding units are suspended to be displaceable under control of the control unit from the supporting station to sealing station and vice versa;
  • said feeding conveyor being configured for, under control of the control unit, feeding the custom sized blank to the supporting station such that the rectangular bottom panel is supported by the folding units;
  • said input conveyor being configured for, under control of the control unit, conveying said at least one article, preferably in horizontal direction onto the rectangular bottom panel supported at the supporting station;
  • control unit being configured for displacing the folding units supporting the bottom panel and the at least one article supported thereon in conveying direction towards the sealing station and for during said displacement operating the folding units for folding side and end panels of the custom sized blank upwardly;
  • a seal applicator apparatus included at the sealing station operatively connected to said control unit for sealing the packaging box; preferably a discharge conveyor for discharging the packaging box with the at least one article;
  • rear pair of folding units is positioned upstream at a longitudinal distance from the front pair of folding units seen in conveying direction;
  • control unit is configured for adjusting the longitudinal distance and/or the transverse distances based on the data indicative for the length and width dimensions, respectively.
  • the input conveyor comprises a number of input sub-conveyors positioned consecutively in conveying direction.
  • the control unit is configured for driving the input sub-conveyors
  • the system comprises a number determining apparatus operatively connected to the control unit for determining the number of articles present on at least one of the input sub- conveyors and for providing data indicative of said number of articles to the control unit.
  • the system comprises a position determining apparatus operatively connected to the control unit for determining at which of the input sub- conveyors the at least one article is present during any given moment during conveying and for supplying data indicative for said determined position to the control unit.
  • the control unit for keeping track of the progress of the articles during the operation of forming packaging boxes around the articles and for comparing the number of articles as determined to be present on a specific input sub- conveyor at a given moment with the expected number and position of articles so that it is possible to check whether the progress takes place correctly.
  • the control unit is also configured for being inputted with the number of articles or items belonging to an order either manually or automatically.
  • control unit is configured for providing an alarm signal in case the number of articles determined to be present on said specific input sub-conveyor differs from the number of said at least one article which is expected to be present thereon.
  • an alarm signal can be used to automatically solve the detected discrepancy or can be used to notify a human operator that an inspection is necessary.
  • a transfer strip is provided adjacent to the downstream end of the input conveyor or the last input sub-conveyor. Such a transfer strip preferably is configured to allow a correct and smooth transfer of items from the input conveyor into the supporting station and onto the bottom panel.
  • control unit is configured for stopping the conveyance of said at least one article by means of the last downstream input sub-conveyor. Temporarily stopping the conveyance of the articles can in some cases be necessary for the control unit to properly time the conveyance of the articles with the feeding of the custom sized blank, so that a correct positioning of the articles on the bottom panel can be obtained.
  • the device for providing data indicative of the overall dimensions comprises a measuring device which is configured for measuring the length, width and height dimensions of said at least one article, preferably during conveying of said at least one article by the input conveyor. In this manner the time needed to automatically form packaging boxes can be decreased leading to a larger operating capacity of the inventive system.
  • the system can include alternative devices for providing data indicative of the overall dimensions for example devices for automatic identification of the article(s) through for example barcode scanning, RFID detection, image recognition and/or looking up the dimensions in databases or even by an operator input, e.g. when handling many small batches of equally sized articles.
  • the input conveyor and the feeding conveyor are positioned such that said at least one article is conveyable in horizontal direction onto the bottom panel supported by the folding units.
  • the blank forming apparatus is positioned below the input conveyor. In this manner the system can be constructed in a compact and in a relatively simple manner.
  • the feeding conveyor comprises a (shallow) S-bend which slopes upwards from the blank forming apparatus to the supporting station so that the conveying direction of the items and the feeding direction of the blank material at least substantially coincide at the level of the output or discharge end of the input conveyor.
  • Forming packaging boxes and packaging items therein can be performed by the system in a relatively easy manner when the control unit and/or the feeding conveyor are configured for feeding the bottom panel into the supporting station such that a center line of the bottom panel in conveying direction is centered between the folding units of the front and rear pair and/or when the control unit and the input conveyor are configured for conveying said at least one article from the input conveyor onto the bottom panel of the custom sized blank such that a leading end of the at least one articles positioned against the leading transverse folding line of the bottom panel.
  • control unit is configured for activating the blank forming apparatus for cutting and creasing blank material into a custom sized blank when said at least one article is present on the last input sub-conveyor. It is then preferred that the control unit is configured for activating the blank forming apparatus only when the number of articles as determined to be present on the last input sub-conveyor equals the expected number of said at least one article, i.e. the number of articles belonging to the order to be processed.
  • the custom sized blank is formed at a stage in which it is almost certain that the correct articles to be packaged are present on the last downstream input sub- conveyor and it can thus be prevented that unintended changes in the number or position of articles necessitate that an earlier formed blank has to be discarded, not only leading to unnecessary waste of material but also leading to an unnecessary decrease of operating capacity.
  • the blank forming apparatus comprises a pair of longitudinal score line applicators for applying longitudinal score lines as folding lines to the blank material between respective panels, a single transverse score line applicator for applying transverse score lines as folding lines between respective panels, a single transverse cutter for cutting the blank material to the length of the custom size blank and a single longitudinal cutter or a pair of longitudinal cutters for cutting the blank material to the width of the custom sized blank, wherein the transverse distance between the pair of longitudinal score line applicators and the transverse distance between the longitudinal cutters is adjustable under control of the control unit based on the data indicative for the width dimension.
  • the single transverse cutter is suspended to be movable along a line which is positioned at such an angle with respect to the feeding direction of the blank material and when the control unit is configured to control the movement of the single transverse cutter along the line and the feeding speed of the feeding conveyor such that the cutter forms a cutting line transverse to the feeding direction, i.e. perpendicular to the side edges of the blank material.
  • a cutter can be realized in the form of a displaceable rotating knife or a displaceable laser beam generator.
  • said blank forming apparatus is configured for, under control of the control unit, cutting and creasing blank material into a custom sized blank having a rectangular bottom panel having a center line (centrally positioned between longitudinal folding lines) substantially parallel to the feeding direction, rectangular side panels and rectangular end panels joined to the bottom panel, rectangular corner panels joined to the end panels, a rectangular top panel joined to one of the end panels, rectangular top side panels joined to the top panel, a rectangular top end panel joined to the top panel and rectangular top corner panels joined to the top end panel, having score lines between the rectangular bottom panel, the rectangular side panels, the rectangular end panels and the rectangular top panel and having cut-outs in line with respective score lines between the corner panels and the adjoining side panels provided by a cutting-out device of the blank forming apparatus.
  • a custom sized blank having such a constitution can be formed relatively simple and by a blank forming apparatus which is relatively simple of construction.
  • the blank forming apparatus and the control unit are configured for cutting and creasing blank material into a custom sized blank having a bottom panel based on the dimensions during feeding of said blank material in feeding direction. In this manner the time needed to automatically form packaging boxes can be decreased leading to a larger operating capacity of the system.
  • the operating capacity can be increased further when the blank forming apparatus comprises a cutting-out device comprising a pair of opposite cut-out knives, said cutout knives being suspended to be displaceable downwards for forming cut-outs between corner panels and adjoining side panels of the custom sized blank, wherein the transverse distance between the opposite cut-out knives is adjustable based on the data indicative for the width and wherein the cutting-out device is configured for displacing the cut-out knives from an inactive position to an active position
  • the cutting-out device comprises a lower transverse guide, wherein the cutout knives comprise an extension in engagement with the lower transverse guide, said lower transverse guide being positioned below the path of the blank material.
  • the blank forming apparatus comprises a pair of longitudinal score line applicators, said longitudinal score line applicators being suspended to be displaceable downwards for applying longitudinal score lines as longitudinal folding lines to the blank material between respective panels, wherein the transverse distance between the longitudinal score line applicators is adjustable under control of the control unit based on the data indicative of the width, and wherein each of the pair of longitudinal score applicators comprises a coupling for mechanically coupling to a respective cut-out knife, said coupling preferably being configured for allowing a relative vertical movement of a cut-out knife and a respective longitudinal score line applicator.
  • the cut-out knives are suspended and guided such that the cutting movement of the knives is substantially perpendicular to the surface of the blank material during the cutting operation.
  • the transverse guides move together with the cut-out knives e.g. during the cutting operation in feeding direction of the blank material.
  • a frame of the system for mounting the cut-out knives can be constructed light-weight while still providing a correct cutting out of blank material.
  • the cutting-out device comprises a pair of cam discs each cooperating with cam followers of a respective cutout knife, each cam disc comprising an outer surface with an outer cam track and an inner surface provided with an inner cam track, one of the outer or inner cam tracks controlling the movement of the cut-out knives from the inactive position to the active position and vice versa and the other one of the outer or inner cam tracks controlling the downward and upward movement of the cut-out knives.
  • each cam disc comprising an outer surface with an outer cam track and an inner surface provided with an inner cam track, one of the outer or inner cam tracks controlling the movement of the cut-out knives from the inactive position to the active position and vice versa and the other one of the outer or inner cam tracks controlling the downward and upward movement of the cut-out knives.
  • the inner cam track and the outer can track can be provided on a single surface of a cam disc.
  • two cam discs on either side can be used of which one comprises the inner cam track and the other one comprises the outer cam track.
  • the angle of the cutting edge of a cut-out knife with a horizontal direction is approximately 15°, while it is advantageous for cutting when the free end of the cut-out knives is provided with an indentation for forming a sharp cutting protrusion at the free end of the cut-out knife.
  • the system comprises a waste conveyor for automatically discharging waste blank material.
  • the waste can e.g. be discharged to a waste container.
  • the input conveyor and/or the control unit is/are configured for positioning said at least one article centrally on the input conveyor.
  • the feeding conveyor and/or the control unit is/are configured for positioning said blank material and said customized blank centrally on the feeding conveyor.
  • control unit is configured for positioning the four folding units at the supporting station downstream of the conveyor in conveying direction relative to one another based on the dimensions by adjusting the longitudinal distance and/or the transverse distances based on the length, width and height dimensions such that the folding units of the front and rear pair are each positioned in a location in which they are able to support a respective corner of the rectangular bottom panel.
  • the folding units and their mutual connection are configured such that during adjusting the transverse distances between the respective folding units the folding units are displaced symmetrically with regard to a central line between the folding units, and preferably such that the adjustment of the transverse distances between the front folding units and the rear folding units is performed synchronously.
  • the device or apparatus for adjusting the relative distances between the folding units can be realized with a relatively simple construction.
  • the control unit is configured for activating the at least one gripping element into the operative mode before folding side and end panels of said custom sized blank upwardly and for keeping the at least one gripping element in the operative mode at least until folding side and end panels of said custom sized blank upwardly has been completed.
  • the at least one gripping element is configured to move freely in a horizontal plane in order to be able to follow possible transverse movements of the rectangular bottom panel.
  • the at least one gripping element comprises a suction cup for exerting underpressure at a respective gripping position at an underside of the rectangular bottom panel, said suction cup preferably being manufactured from flexible material. It is then preferred that the suction cup is suspended for being raised from a lower inoperative position to an operative position in contact with the bottom panel for gripping and supporting the bottom panel, and that the control unit preferably configured for activating the underpressure in the suction cup before it contacts the bottom panel, such that the suction cup can reproducibly grip the bottom panel without changing the position of the bottom panel in the supporting station.
  • the front pair of folding units are simultaneously drivable by a front motor from the supporting station towards the sealing station and vice versa
  • the rear pair of folding units are simultaneously drivable by a rear motor from the supporting station towards the sealing station and vice versa
  • the front and rear folding units are coupled such that their transverse distances are simultaneously adjustable by a transverse motor
  • the control unit is configured for adjusting the longitudinal distance and the transverse distances based on the data indicative for the length, width and height dimensions by accordingly controlling the front, rear and transverse motors such that the folding units of the front and rear pair are each positionable in a location in which they are able to support a respective corner of the rectangular bottom panel.
  • control unit is configured for adjusting the longitudinal distance between the rear and front folding units during feeding of the custom sized blank into the supporting station, preferably by starting the displacement of the front pair of folding units towards the sealing station earlier than the displacement of the rear pair of folding units. Since adjusting of the longitudinal distance between the front and rear folding units takes place during displacement of the front folding units the time needed to fold a box can be reduced so that the process capacity can be increased.
  • control unit is configured for raising the suction cup substantially simultaneously with starting displacing the front pair of folding units towards the sealing station so that correct gripping can be realized and processing capacity can be increased.
  • control unit is configured for adjusting the transverse distances between respective folding units during said displacement of the folding units from the sealing station towards the supporting station.
  • the correct transverse position of the folding units to support a next custom sized bottom panel at the corners thereof can be assumed before the four folding units reach the supporting position thereby allowing increasing the operating capacity.
  • the transverse distances are first adjusted to a default transverse distance, e.g. in case the data for the transverse distance for the next custom sized bottom panel is not available yet and/or to avoid collision with in particular corner portions of panels of the blank which bend too much downwards.
  • control unit and the system are configured for displacing the folding units from the supporting station towards the sealing station and vice versa independently from the relative positioning of the folding units such that the flexibility and the operating speed of the method can be increased.
  • Forming packaging boxes and packaging items therein can be performed relatively fast in an embodiment of a system according to the invention when the control unit is configured for feeding the bottom panel onto the at least four folding units without interruption after cutting and creasing blank material into a custom sized blank.
  • the processing speed can be increased when the control unit is configured for conveying the at least one article onto the bottom panel while the custom sized blank is being fed into the supporting station.
  • the system preferably comprises a top panel raiser operatively connected to the control unit for, during transport of the bottom panel from the supporting station towards the sealing station, gradually raising the top panel.
  • a top panel raiser operatively connected to the control unit for, during transport of the bottom panel from the supporting station towards the sealing station, gradually raising the top panel.
  • the top panel is at the same time supported and thus prevented from inadvertently bending downwards.
  • gradually raising the top panel can promote further folding of the top panel.
  • the step of gradually raising the top panel is preferably performed by means of a top panel raiser, preferably comprising a slanting belt extending from the supporting station to the sealing station.
  • control unit when the control unit is configured for controlling the blank forming apparatus for cutting and creasing blank material into a custom sized blank such that a custom sized blank is formed having a top panel downstream of the bottom panel and when the system comprises a top panel folder downstream of the supporting station operatively connected to the control unit, the top panel folder can be configured to be displaceable in height at a top folder level above the level defined by the bottom panel based on the data indicative for the height dimension and to be displaceable from and towards the supporting station, the control unit can be configured for displacing the top panel folder in a direction from the sealing station towards the supporting station while the folding units are displaced from the supporting station towards the sealing station for folding the top panel into a position which is substantially parallel to the rectangular bottom panel in a reliable and quick manner.
  • the top panel folder comprises a top pair of top folding units, which top folding units are suspended to be displaceable with respect to one another for adjusting a top transverse distance between the top folding units based on the data indicative for the width dimension, and the control unit is configured for activating the top folding units for folding down top side panels and/or a top end panel and/or top corner panels after the top panel has been folded into the position which is substantially parallel to the rectangular bottom panel.
  • a correct folding of top end, side and corner panels can be obtained in an embodiment of a system according to the invention when the control unit is configured for, during activation of the top folding units, reversing the displacement of the top panel folder so that the top panel folder can be displaced in a direction towards the sealing station.
  • the top panel folder is provided with at least one controllable rod, preferably at least two controllable rods, wherein the control unit is configured for activating the controllable rod to engage a rear wall of the custom sized box, and preferably with at least one further controllable rod, preferably at least two controllable rods, which after activating of the top folding units by the control unit is/are activated to engage a (respective) side wall of the custom sized box recoiling of the top end panel and the top side panels can be prevented and in addition the rods engaging the rear wall of the box at least can assist in further transport of the box towards the sealing station.
  • controllable rod(s) engaging the rear wall can under control of the control unit be used for further transport towards the sealing station together with an additional supporting element extending centrally between the folding units and extending from the supporting station to the sealing station such that the folding units can be deactivated and already be returned to the supporting station after the rod(s) has (have) taken over transport.
  • the supporting element comprises a central stationary element and a pair of side supporting elements each at either side of the stationary supporting element, wherein the side support elements are configured such that the distance between the side support elements is adjustable under control of the control unit based on the data indicative for the width dimension.
  • each of the folding units of the front and rear pair and preferably the top pair is provided with controllable end panel folding flaps and/or controllable side panel folding flaps and/or a controllable initiator for initiating the folding of a corner panel.
  • the seal applicator comprises displaceable seal applicator units and the control unit is configured for displacing the seal applicator units based data indicative for the length, width and/or height dimensions. In this manner sealing boxed of different dimensions can be realized in a correct and automatic manner.
  • Fig. 1 is a schematic top view in perspective of a system 1 for packaging items a box and for packaging the items therein simultaneously with the formation of said packaging box wherein the blank material from which the box is folded remains stationary during folding.
  • Figs. 2A to 2G schematically show views in perspective of various stages of folding a custom sized box in which only the blank is shown.
  • Figs. 3A to 3E schematically show views in perspective of various stages of activation of a folding unit provided with a suction cup, folding flaps and a corner flap initiator.
  • Figs. 4A to 4M show schematic top views in perspective of a various stages of a system 61 for packaging items in a box and for packaging the items therein
  • Figs 5A and 5B schematically show top views in perspective of an embodiment of a system 61 ' for packaging items in a box and for packaging the items therein simultaneously with the formation of said packaging box wherein during folding of the box the blank material can be either transported or remain stationary.
  • Figs. 6A to 6F schematically shows views in perspective of a blank forming apparatus 73 for cutting and creasing blank material into custom sized blanks which apparatus 73 can be used autonomously or in combination with any one of the systems 1 , 61 , 61 ' shown in Figs. 1 , 4 and 5, respectively.
  • Fig. 7 shows a schematic side view in cross-section of the region around the transfer strip 71 between the input conveyor and the supporting station of the system 61 of Fig. 4 in more detail.
  • Fig. 8 shows a schematic view in perspective of a top panel folder 86 with slanting belt which top panel folder 86 can be used autonomously or in combination with any one of the systems 1 , 61 , 61 ' shown in Figs. 1 , 4 and 5, respectively.
  • Figs. 9A to 9D schematically show views in perspective of various stages of activation of a top folding unit provided with a pushing element 142, folding flaps and a corner flap initiator.
  • Fig. 10 shows a modification of the top panel folder shown in Fig. 8.
  • Fig. 11 shows a modification of the top panel folder shown in Fig. 8.
  • Fig.s 12A to 12D show a top panel folder comprising an arrangement for correcting misalignment or mis-positioning of the top panel.
  • Fig.s 13A and 13B show a top panel guide comprising a rolling element.
  • a schematic top view in perspective of a system 1 for packaging items in a box is shown.
  • the system 1 comprises a control unit 2 comprising a processing unit 3 for controlling the operation of the system 1.
  • the control unit 2 can furthermore comprise a console 4 with control buttons e.g. for manually inputting data and a display 5.
  • the console 4 is placed at the right hand side of the frame 6A downstream with regard to the conveying direction of the feeding conveyor 8.
  • the console 4 can be positioned at another side of the frame 6A e.g. depending on the direction in which folded boxes are discharged from the supporting station and depending on the mounting position of auxiliary devices, such as e.g. a top panel folder, a sealing apparatus etc.
  • the system 1 furthermore comprises a box folding apparatus 6 for folding a box from a blank 40 (Fig. 2) having a rectangular bottom panel 41 and further panels joined to the bottom panel by folding lines.
  • the box folding apparatus 6 is operatively connected to the control unit 2.
  • the box folding apparatus 6 is able to folding a box from differently shaped blanks which at least comprises a rectangular bottom panel and two side panels and two end panels and can be used to fold a so called open box which can optionally closed with a separate cover or lid.
  • a blank as shown in Fig. 2 will be used to describe the operation of the box folding apparatus 6.
  • the blank 40 (see Fig. 2A) has a rectangular bottom panel 41 , rectangular side panels 42, 43 and rectangular end panels 44, 45 joined to the bottom panel 41 , rectangular corner panels 46, 48 joined to the end panel 44, rectangular corner panels 47, 49 joined to the end panel 45, a rectangular top panel 50 joined to the end panel 44, rectangular top side panels 51 , 52 joined to the top panel 50, a rectangular top end panel 53 joined to the top panel 50 and rectangular top corner panels 54, 55 joined to the top end panel 53.
  • Fig. 2A has a rectangular bottom panel 41 , rectangular side panels 42, 43 and rectangular end panels 44, 45 joined to the bottom panel 41 , rectangular corner panels 46, 48 joined to the end panel 44, rectangular corner panels 47, 49 joined to the end panel 45, a rectangular top panel 50 joined to the end panel 44, rectangular top side panels 51 , 52 joined to the top panel 50, a rectangular top end panel 53 joined to the top panel 50 and rectangular top corner panels 54, 55 joined to the top end panel 53.
  • the rectangular bottom panel 41 has a length L and a width W
  • the rectangular side panels 42, 43 each have a length L and a width 1 ⁇ 2H
  • the rectangular end panels 44, 45 each have a width W and a length H
  • the rectangular corner panels 46, 48 each have a length H and a width 1 ⁇ 2H
  • the rectangular top panel 50 has a length L and a width W
  • the rectangular top side panels 51 , 52 have a length L and a width 1 ⁇ 2H
  • the rectangular top end panel 53 has a length 1 ⁇ 2H and a width W
  • the rectangular top corner panels 54, 55 have a width and a length of 1 ⁇ 2H.
  • Cutouts 56 are present between the respective corner panels and the adjoining side panels and have a width of 1 ⁇ 2H and a length G which is sufficient for allowing a correct folding of the panels with respect to one another. As can be seen the cut-outs 56 are in line with respective transverse score lines.
  • the cut-outs can be realized by taking away blank material but can also be formed by incisions in the blank material without taking away blank material.
  • the dimensions can be a little larger (by an amount of a few millimeters) in order to ensure a correct folding of the box while still providing sufficient interior volume of the box for the articles to be packaged.
  • the width of the top side panels and the length of the top end panel is a certain amount, preferably about 1 cm to 2 cm, larger than 1 ⁇ 2H so that an overlapping part is obtained, which protects the items to be packaged when a seal of the box is opened.
  • the system 1 comprises a support station 7 which in Fig. 1 is formed by the box folding apparatus 6 mounted within a frame construction 6A.
  • the support station 7 comprises a support for a rectangular bottom panel 41 of a blank 40 which can be put onto the support by hand or can be transported thereon via a feeding conveyor 8.
  • the support is formed by a gripping device 9 having four controllable gripping elements 10, 11 , 12 and 13. In case larger blanks are to be folded a central supporting bar 8A can be provided.
  • the gripping device 9 is operatively connected to the control unit 2 which is configured for activating the gripping elements 10 - 13 into an operative mode for gripping the bottom panel 41 and for deactivating the gripping elements 10 - 13 for releasing the bottom panel 41.
  • the relative distance between each of the four gripping elements 10 - 13 is adjustable such as to define a respective comer of a rectangular support plane having a length I and a width w such as to support the rectangular bottom panel 41.
  • the support plane thus in fact is a virtual plane which is defined by the corners points formed by the gripping elements 10 - 13.
  • the gripping elements 10 and 11 are positioned stationary with respect to the feeding conveyor, meaning that they are mounted at a fixed distance from an output end of the feeding conveyor 8.
  • the relative distance between the gripping elements 10 and 11 defining the width w is adjustable.
  • the gripping elements 12 and 13 are positioned 15 moveably with respect to the gripping elements 10, 11 and thus with respect to the feeding conveyor, meaning that they are mounted at a distance from the gripping elements 10, 11 which is adjustable.
  • the relative distance between the gripping elements 12 and 13, defining the width w is also adjustable.
  • each gripping element 10 - 13 is provided with folding elements 14, 15, 16 (for clarity reasons in Fig. 1 only shown for the gripping element 12) for folding end, side and corner panels upwardly with respect to the rectangular bottom panel 41.
  • the four gripping elements 10 - 13 including the folding units 14 - 16 are thus positioned at the corners of a rectangle and thus form a support surface for the bottom panel 41.
  • each gripping element 10 - 13 is provided with a corner connection piece 17 (for clarity reasons in Fig. 1 only shown for the gripping element 10) which interconnects the gripping element 10 or 11 with the adjacent downstream gripping element 12 or 13, respectively and the adjacent gripping element 11 seen in a direction transverse to the conveying direction of the feeding conveyor 8 by means of sliding rods 18A, 18B and 9A, 9B.
  • Each corner connection piece 17 therefore has a transverse sliding sleeve 20 that slidably supports a part of a respective transverse sliding rod 19A, 19B and a longitudinal sliding sleeve 21 that slidably supports a part of a respective longitudinal sliding rod 8A, 8B.
  • connection pieces 17 are vertically positioned above the sliding rods 18A, B thereby providing additional stability to the gripping elements 10 - 3.
  • different kinds of connection pieces can be used.
  • the distance I between the two transverse connecting folding bars 19A, 19B is adjustable to correspond to the length dimension L of the bottom panel and the distance w between the two longitudinal connecting bars 18A, 18B is adjustable to correspond to the width dimension W of the bottom panel 41.
  • control unit 2 which control unit 2 is operatively connected to the motors M1 , M2.
  • control buttons on the console 4 it is possible by using the control buttons on the console 4 to set the distances by manual input.
  • the other gripping elements are similarly constructed. However, in embodiments where e.g. the weight of the items on the bottom panels prevents the bottom panel from shifting during upward folding end and side panels it is possible to only provide one rear folding unit and one front folding unit with a gripping element or even to only provide one of the at least four folding units with a gripping element.
  • the gripping element 12 is shown in Fig. 3A in a starting position in which a blank can be positioned thereon.
  • the gripping element 12 comprises a suction cup 22 of flexible material, which is activated under control of the control unit 2 for gripping and fixation at a respective gripping position of the bottom panel e.g.
  • the underpressure in the suction cups is activated by the control unit 2 before folding respective panels of the blank upwardly in order to prevent the blank from unwantedly lifting up from the suction cups.
  • the control unit keeps the suction cup activated at least until the panels are completely folded upwards.
  • the gripping element 12 is provided with an end panel folding flap 14, a side panel folding flap 15 and an initiator 16 for initiating the upward folding of a corner panel all of which are controllable by the control unit 2.
  • the suction cup 22 is mounted displaceable within the gripping element 12 and is provided with a rod like extension 23 which is guided in a slot 24 of a plate 24A which slot 24 is open at the underside and which plate 24A is mounted so as to move together with the end panel folding flap 14.
  • each suction nozzle comprises a single suction head.
  • each suction nozzle can in other embodiments comprise multiple suction heads and/or additional support surfaces, such as support surface 25, top surfaces of which lie in the support plane.
  • control unit 2 controls the gripping element 12 with the controllable folding elements such that panels of blanks with the configuration as shown in Fig. 2 are consistently and reproducibly folded in correct order in the following manner.
  • Fig. 3B first a body of the gripping element
  • the control unit 2 can ensure that the corner panels 46 - 49 are first at least partly folded upwards. (The situation in which the corner panels are partly folded upwards is shown in Fig. 2B.) Thereafter the control unit 2 activates the end panel folding flap 14 such that the end panel 44 is caused to be folded partly upwards and the side panel folding flap 15 to fold the side panel 42 partly upwards.
  • the initiator 16 is raised over a
  • the plate 24A is raised such that the rod like extension 23 of the suction cup is free from the slot 24, meaning that the suction cup 22 is mounted so as to move freely in a horizontal plane in order to be able to follow possible transverse movements of the bottom panel during upwardly folding of the respective panels ensuring a correct gripping throughout the folding operation.
  • the end panel folding flap 14, the side panels folding flap 15 and the initiator 16 are mounted such in the gripping element such that the above described activation can be realized by using only one activator 26.
  • the end and side panel folding flaps and initiator can be driven by separate drivers which are separately activated by the control unit.
  • the end pane folding flap 14 and the side panel folding flap 15 are folded so as to take in a vertical position as shown in Fig. 3E, corresponding to a folded blank is shown in Fig. 2D.
  • Folding the top panel 50 over the upstanding side panels as shown in Fig.s 2E and 2F can be performed manually or by means of any known top panel folder but preferably by an inventive top panel folder to be described later.
  • the box can be closed by applying a tape 74 over the single seam, as shown in Fig. 2G.
  • This can be performed at the supporting station but can also be done at a separate sealing station.
  • the system can comprises a transferring means operatively connected to the control unit and preferably integrated in the top panel folder for transferring a folded box e.g. in transverse direction from the supporting station to the sealing station.
  • FIG. 4A a schematic side top view in perspective of a system 61 for automatically forming packaging boxes and for packaging at least one article therein, in this embodiment simultaneously with the formation of said packaging boxes in accordance with the invention is shown.
  • the system 61 comprises a control unit 62 comprising a processing unit 63 for controlling the operation of the system 61.
  • the control unit 62 can furthermore comprise a console 64 with control buttons e.g. for manually inputting data and a display 65.
  • Articles or items 67, 68 to be packaged are substantially horizontally conveyed in conveyance direction C indicated by the arrow by an input conveyor 69, which can be realized by any known means, such as endless conveyor belts, roller conveyors, etc.
  • the articles to be conveyed can be positioned centrally on the input conveyor 69 and during conveyance this central position can be maintained.
  • the input conveyor 69 comprises a number of input sub-conveyors of which only two 69A, 69B have been shown.
  • the input sub-conveyors 69A, 69B are positioned consecutively in conveying direction, and include a last downstream input sub-conveyor 69B.
  • Indicators 70A-C (of which 70B, C are shown partly in Fig.
  • Such indicators 70A-C can be in the form of light sensors, cameras or any other known means.
  • data from encoders driving the input sub-conveyors can be used in determining the position of the articles.
  • Such indicators 70 can in combination with data from the control unit 62, to which the indicators are communicatively connected for providing data indicative for said determined position thereto, also be used to indicate a location on the input conveyor 69 where items belonging to an order for a customer are deemed to be present at any given moment in time.
  • the input sub-conveyors 69A, B are configured to be driven independently from each other by means of the control unit based on information provided by the indicators 70.
  • the indicators 70 optionally in combination with weighing means can determine the number of articles present on a specific input sub-conveyor and provide data indicative of said number to the control unit 62.
  • the control unit 62 can give an alarm signal to an operator and/or can deactivate the input conveyor 69 simultaneously with said alarm signal.
  • the number of articles belonging to an order of a customer can e.g. by automatically inputted in the control unit during ordering.
  • Indicator 70A can be configured as measuring device for measuring the length, width and height dimensions of the items during conveyance of said at least one article by the input conveyor, such that the capacity of the system can be increased.
  • the system 61 is furthermore provided with a transfer strip 71 adjacent to the downstream end of the last downstream input sub-conveyor 69B (see also Fig. 7).
  • the transfer strip 71 preferably lies in the extension of the last downstream input sub- conveyor 69B.
  • Articles to be packaged can be conveyed by means of the last downstream input sub-conveyor 69B onto and over the transfer strip 71.
  • the transfer strip 71 not drivable.
  • the last downstream input sub-conveyor can be stopped by the control unit in case this is required for further conveyance of the articles onto a bottom panel of a blank.
  • Transport of items or articles belonging to an order of a customer onto a specific input sub-conveyor can be realized by (not-shown) transport means which e.g. can be formed by conveyor belts which are oriented transverse to the input conveyor 69 and the operation of which can also be controlled by the control unit 62.
  • the measurement device 70A is included for measuring the dimensions and optionally weight of items 67, 68 to be packaged and for providing data indicative for the measured dimensions and optionally weight to the control unit 62.
  • the measurement device 70A measures the length, width and height of the items 67, 68 to be packaged while the articles are conveyed such that the capacity of the system can be increased.
  • the measurement device 70A is communicatively connected to the control unit 62 for providing data indicative for the measured dimensions to the control unit 62. Such a connection can be hardwired or wireless.
  • the system 61 furthermore comprises a blank forming station 72 comprising a blank forming apparatus 73 for cutting and creasing blank material into a custom sized blank for example from blank material which is fed out of a stock or storage 75 of default blanks.
  • the blank forming apparatus 73 is positioned below the input conveyor 69, and preferably such that the conveying direction C of said articles 67, 68 is at least substantially parallel to the feeding direction F of the blank material.
  • the stock 75 of default blanks is shown in Fig. 4A as a roll of endless blank material, such a stock may also be provided by zigzag folded blank material, a stack of separate default blanks or stocked otherwise.
  • the blank forming apparatus 73 is communicatively connected to the control unit 62, which controls the blank forming apparatus 73 for cutting and creasing blank material into a custom sized blank having a rectangular bottom panel at least based on the data indicative for the measured dimensions as provided by the measurement device 70A.
  • the blank forming apparatus 73 will be more detailed described with reference to Fig. 6 and is controlled by the control unit 62 for cutting and creasing blank material into a custom sized blank 40 as shown in Fig.
  • FIG. 2A having a rectangular bottom panel 41 , rectangular side panels 42, 43 and rectangular end panels 44, 45 joined to the bottom panel 41 , rectangular corner panels 46, 48 joined to the end panel 44, rectangular corner panels 47, 49 joined to the end panel 45, a rectangular top panel 50 joined to the end panel 44, rectangular top side panels 51 , 52 joined to the top panel 50, a rectangular top end panel 53 joined to the top panel 50 and rectangular top corner panels 54, 55 joined to the top end panel 53.
  • the rectangular bottom panel 41 has a length L and a width W
  • the rectangular side panels 42, 43 each have a length L and a width 1 ⁇ 2H
  • the rectangular end panels 44, 45 each have a width W and a length H
  • the rectangular corner panels 46, 48 each have a length H and a width 1 ⁇ 2H
  • the rectangular top panel 50 has a length L and a width W
  • the rectangular top side panels 51 , 52 have a length L and a width 1 ⁇ 2H
  • the rectangular top end panel 53 has a length 1 ⁇ 2H and a width W
  • the rectangular top corner panels 54, 55 have a width and a length of 1 ⁇ 2H.
  • Cutouts 56 are present between the respective corner panels and the adjoining side panels and have a width of 1 ⁇ 2H and a length G which is sufficient for allowing a correct folding of the panels with respect to one another. As can be seen the cut-outs 56 are in line with respective transverse score lines. Again, dependent on the (stiffness) of the material of which the blanks are made the dimensions can be a little larger (by an amount of a few millimeters) in order to ensure a correct folding of the box while still providing sufficient interior volume of the box for the articles to be packaged. This means that the above given dimensions of the custom sized box are a small amount larger than the measured length, width and height dimensions of the articles to be packaged.
  • the width of the top side panels and the length of the top end panel is a certain amount, preferably about 1 cm to 2 cm, larger than 1 ⁇ 2H so that an overlapping part is obtained, which protects the items to be packaged when a seal of the box is opened.
  • Feeding of blank material is performed by a feeding conveyor 76 which is operatively connected to the control unit 62.
  • the feeding conveyor 76 both transports the blank material from the storage 75 to the blank forming station 72 and transports custom sized blanks from the blank forming station 72 to a supporting station 77.
  • the feeding conveyor 76 can be arranged for feeding the blank material and the custom sized blank centrally positioned thereon towards the supporting station 77.
  • the feeding conveyor 76 can e.g.
  • the blank forming apparatus 73 is positioned below the input conveyor the feeding conveyor 76 transports the blank upwards, preferably via a (shallow) S-bend 76A which slopes upwards.
  • Waste blank material remaining after formation of the custom sized blank falls down on a waste conveyor 79 and is discharged via this waste conveyor 79 preferably in a direction WM transverse to the conveying direction C.
  • the folding units 80-83 are is provided with a controllable suction cup as gripping element for gripping the bottom panel and are constructed as shown and described with reference to Fig. 3.
  • a controllable suction cup as gripping element for gripping the bottom panel and are constructed as shown and described with reference to Fig. 3.
  • at least one of the folding units can be provided with a suction cup.
  • the folding units 80-83 are thus operatively connected to the control unit 62 which is configured for activating said the folding units and the suction cup into an operative mode for gripping the bottom panel and for deactivating the suction cup for releasing the bottom panel.
  • the four folding units 80-83 comprise a front pair of folding units 82, 83 and a rear pair of folding units 80, 81 positioned upstream at a longitudinal distance I from the front pair of folding units 82, 83 seen in conveying direction.
  • the folding units 82, 83 of the front pair and the folding units 80, 81 of the rear pair are positioned at the same transverse distance w from each other, which distance is adjustable under control of the control unit 62 based on the data indicative for the measured length and width dimensions, respectively.
  • the control unit 62 can adjust the longitudinal distance and the transverse distance between the folding units 80-83 such that the folding units are able to support a respective corner of a bottom panel 41 of the custom sized blank 40.
  • the transverse distance between the front folding units and the transverse distance between the rear folding units is different.
  • control unit 62 can control the rear pair of folding units 80, 81 such that their distance with regard to the transfer strip 71 stays constant throughout folding
  • all the folding units 80-83 are suspended to be displaceable under control of the control unit 62 from the supporting station 77 to a sealing station 84 and vice versa.
  • the front folding units 82, 83 are simultaneously drivabie by a front motor FM (see Fig. 5B) from the supporting station 77 towards the sealing station 84 and vice versa
  • the rear folding units 80, 81 are simultaneously drivabie by a rear motor RM from the supporting station 77 towards the sealing station 84 and vice versa, independent from the displacement of the front folding units.
  • the front and rear folding units are coupled by means of sliding rods 88A, 88B and 89A, 89B such that by means of a single transverse motor 87 (Fig. 5B) relative transverse displacement of the folding units is allowed by means of a sliding engagement of the sliding rods or bars and the connection pieces of the folding units.
  • the control unit 62 can control the motors FM, RM and 87 independently from each other so as to adjust the longitudinal distance and the transverse distance such that the folding units of the front and rear pair are each positionable in a location in which they are able to support a respective corner of the rectangular bottom panel.
  • front folding units are drivabie in longitudinal direction
  • the sealing station 77 is thus positioned downstream of the supporting station 77 and comprises a seal applicator apparatus 85 which is operatively connected to said control unit 62 for sealing a folded packaging box.
  • a top panel folder 86 is positioned downstream of the supporting station 77, which top panel folder 86 is operatively connected to the control unit 62.
  • the top panel folder 86 is displaceable in height at a top folder level TL above the level defined by the bottom panel 41 , which height is adjustable based on the data indicative for the measured height dimension.
  • the top panel folder 86 is displaceable from and towards the supporting station 77 and in particular the control unit 62 is configured for displacing the top panel folder 86 in a direction from the sealing station 84 towards the supporting station 77 while the folding units 80-83 are displaced from the supporting station 77 towards the sealing station 84 for folding the top panel 50 into a position which is substantially parallel to the rectangular bottom panel 41 , as will be described below.
  • an order of a customer comprises three items 67.
  • the items 67 are first positioned on an input sub-conveyor (not-shown) and are then transported by the input conveyor 69 until the items 67 arrive at the last downstream sub-conveyor 69B where the conveyance of the items 67 is temporarily stopped.
  • the measuring device 70A measures the width, length and height of all the items 67 together and sends data indicative for these dimensions to the control unit 62.
  • the indicator 70C determines the number of items 67 present on the last sub- conveyor 69B and sends this information to the control unit 62.
  • the control unit 62 compares the number of items present on the last downstream sub- conveyor 69B with the number of items belonging to the order of the customer and in case the numbers match then the control unit 62 activates the feeding conveyor 76 to transport blank material from the storage 75 and furthermore activates the blank forming apparatus 73 (which will be described in detail with regard to Fig. 6) for cutting and creasing blank material into a custom sized blank 40 as indicated in Fig. 2 during feeding of the blank material in feeding direction F.
  • the four folding units 80-83 are positioned at the supporting station 77 and the transverse distance w between the folding units of the front pair and rear pair is already adjusted to the measured width and thus also to the width W of the bottom panel.
  • the longitudinal distance I between the front and rear pair is adjusted to an initial distance which can be smaller than the length of the bottom panel as determined on the measured length. Preferably, this initial distance is set to the smallest length dimension of bottom panels to be processed in the system.
  • the feeding conveyor 76 feeds the custom sized blank to the supporting station 77 such that the top end panel 53 is first transported over the folding units 80 -83 and the rest of the blank follows. Based on the measured dimensions and the feeding speed of the feeding conveyor 76 the control unit 62 activates the front motor FM for the front folding units 82, 83 to start moving the front folding units 82, 83 in the direction of the sealing station and activates the suction cups of the folding units 82, 83 (the position as indicated in
  • the suction cups of the front folding units 82, 83 grip the two respective corners of the bottom panel 41 during feeding of the blank by the feeding conveyor 72.
  • the front folding units 82, 83 are accelerated to a speed matching the feeding speed of the feeding conveyor and thus the front folding units 82, 83 not only support the blank but also transport the blank together with the feeding conveyor.
  • the rear folding units 80, 81 remain deactivated.
  • the control unit is configured for adjusting the longitudinal distance I during feeding of the blank into the supporting station by starting the displacement of the front folding units earlier than the displacement of the rear folding units.
  • the control unit 62 activates the last downstream sub-conveyor 69B at with such timing that the items are transported in horizontal direction onto the rectangular bottom panel supported at the supporting station such that the items 67 are positioned as close as possible to the folding line connecting the bottom panel 41 bottom end panel 44.
  • Fig. 7 a schematic side view in cross-section of a part of the S- bend 76A, the transfer strip 71 adjacent to the downstream end of the last downstream input sub-conveyor 69B, a connection piece 17' of one of the rear (deactivated) folding units and the blank 40 are shown at a moment during feeding of the blank 40 into the supporting station.
  • Fig. 7 a schematic side view in cross-section of a part of the S- bend 76A, the transfer strip 71 adjacent to the downstream end of the last downstream input sub-conveyor 69B, a connection piece 17' of one of the rear (deactivated) folding units and the blank 40 are shown at a moment during feeding of the blank 40 into the supporting station.
  • the system is configured such that the transfer strip 71 lies in the extension of the last downstream input sub-conveyor 69B so that items 67 can be conveyed by means of the last downstream input sub-conveyor 69B horizontally onto and over the transfer strip 71 and onto the blank.
  • the situation which is obtained at this moment and in which the top panel folder 86 is positioned in its start position is indicated in Fig. 4A.
  • the bottom panel is thus fed into the supporting station 77 such that a center line of the bottom panel in conveying direction is centered between the folding units of the front and rear pair and in addition the items are conveyed centralized.
  • control unit 62 activates the front motor RM for the rear folding units 80, 81 to start moving the rear folding units 80, 81 in the direction of the sealing station and activates the suction cups of the rear folding units 80, 81 (the position as indicated in Fig. 3B) with such a timing that the suction cups of the rear folding units 80, 81 grip the two respective corners of the bottom panel 41 during feeding of the blank by the feeding conveyor 72.
  • the control unit can be configured for starting raising the suction cup substantially simultaneously with starting displacing the front pair of folding units towards the sealing station.
  • the rear folding units 80, 81 are accelerated to a speed matching the speed of the front folding units 5 82, 83.
  • This situation in which the suction cups of the rear folding units have just gripped the bottom panel is indicated in Fig. 4B in which it is indicated that the control unit 62 has timed the activation of the RM such that the distance U between the front and rear folding units is such that the folding units support the respective corners of the bottom panel having a length L.
  • the front and read folding units 80 - 83 fully support the blank and the blank is not supported or transported anymore by the feeding conveyor.
  • the folding units thus not only function as a support for the blank but also as a transport means for the blank from the support station 77 to the sealing station 84.
  • the feeding conveyor 76 which fed the blank into the supporting station without interruption of the feeding movement does not transport the blank anymore.
  • the top panel 50 of the blank has been raised during the initial transport of the bottom panel from the supporting station towards the sealing station. Raising of the top panel 50 is effected by means of a top panel raiser 90 which is operatively controlled by the control unit 62 and which comprises a slanting belt 91 (see Fig. 5) extending from the supporting station to the sealing station.
  • the slanting belt is not indicated in Fig. 4 for convenience of drawing, in addition the distance between the supporting station and sealing station has been somewhat extended in the Fig.s 4A-4M to more clearly indicate the distinct steps.
  • a more realistic view of the scales is shown in Fig.s 5A, 5B.
  • the slanting belt functions as a support for the top panel and prevents it from unwantedly bending downwards along the respective folding line.
  • the supporting element 92 can comprise a central stationary element 92A (Fig. 5A) and a pair of side supporting elements 92B, 92C each at either side of the central stationary element 92.
  • the side support elements 92B, 92C are configured such that the distance between them is adjustable under control of the control unit 62 based on data indicative for the measured width dimension to ensure proper support for heavier articles 67.
  • the folding flaps of the folding units 80-83 have not been activated and may preferably be only activated after all the suction cups have gripped the bottom panel in order to ensure a correct folding.
  • the control unit 62 first displaces all the folding units over a safety distance SD towards the sealing station 84 before it activates the folding elements. This safety distance can be dependent on the measured length and height dimensions. In Fig. 4C the situation is indicated in which the folding units have just reached this safety distance SD and at this moment the control unit 62 is going to activate the folding elements in the same manner as described with reference to Fig. 3.
  • the folding units 80-83 are activated such that the folding flaps fold corner, side and end panels of the custom sized blank upwardly in the same manner as described with reference to Fig.s 2 and 3.
  • Fig.s 4D and 4E folding of the panels upwardly as indicated schematically.
  • the folding units / gripping elements 80- 83 are configured to move freely in a horizontal plane in order to be able to follow possible transverse movements of the rectangular bottom panel during folding of the panels.
  • the top panel folder has been activated by the control unit to move in a direction towards the supporting station 77.
  • Fig. 4F the situation is shown in which the top panel folder 86 has been transported over such a distance in the direction towards the folding units and the top panel that top panel guides 93 (for convenience of drawing not shown in Fig. 4F but indicated in Fig. 8) have come into contact with the top panel 50 and have taken over the support thereof as provided by the slanting belt.
  • the control unit 62 controls the upward movement of the top panel raiser 90 and movement of the top panel folder 83 towards the supporting station such that the top panel has reached a sufficient height to enable the top panel guides 93 to engage the top panel correctly. This ensures further folding the top panel 50 over the bottom panel 41 and the articles positioned thereon.
  • the top panel folder 86 is in this embodiment linearly moveable along a rail construction 186, 286 (see Fig. 4I).
  • the top panel guides 93 can be mounted pivotally on the top panel folder 86. During further transport of the top panel folder in the direction of the supporting station and further displacement of the folding units towards the sealing station the top panel will be folded into a horizontal position as shown in Fig. 4G. At this position a top pair of top folding units 94, 95 of the top panel folder 86, which top pair folding units 94, 95 are configured to be displaceable with respect to one another under control of the control unit 62 for adjusting a top transverse distance there between based on the data indicative for the measured width dimension, are lowered to come into contact with respective corners of the top panel 50.
  • These top folding units 94, 95 are described in more detail with reference to Fig. 9.
  • the control unit 62 activates the top folding units 94, 95 for folding down top corner panels 54, 55, top side panels 51 , 52 and a top end panel 53 as indicated in Fig. 4H.
  • the control unit 62 lowers the top panel raiser 90.
  • the top corner, end and side panels are completely folded downwards and the top panel raiser has been completely lowered, as indicated in Fig. 4I.
  • the top folding units 94, 95 are provided with controllable rods 96, 97 and 98, 99 (see also Fig. 9A) which are activated, i.e. lowered, under control of the control unit 62 after the box is completely folded as shown in Fig. 4J.
  • the rods 96 and 97 engage the side surfaces of the box, whereas the rods 98, 99 engage the rear surface of the box, i.e. the surface which is directed towards the sealing station.
  • the control unit 62 is thus configured for activating the suction cups of flexible material into the operative mode such that they grip the bottom panel at respective gripping position at its underside before corner, side and end panels of said custom sized blank are folded upwards. Furthermore, the control unit is configured for keeping the suction cups gripping element in the operative mode at least until folding of corner, side and end panels of the custom sized blank upwardly has been completed, but preferably until also top corner, top side and top end panels have been completely folded downwards.
  • the suction cups of the folding units 80-83 are deactivated for releasing the bottom panel and the rear and front motors of the four folding units are controlled by the control unit 62 such as to reverse to movement of the folding unit to return them to the supporting station 77, as indicated in Fig. 4K where the next custom sized blank is already waiting.
  • the transport of the box 67' towards and into the sealing station is then completed by the movement of the top panel folder and the rods 96-99, as indicated in Fig. 4M.
  • the control unit 62 activates the transverse motor 87 for adjusting the transverse distance between folding units 80-83 during displacement of the folding units in a direction from the sealing station back to the supporting station.
  • the front motor FM and the rear motor RM can be activated independently to adjust the relative positioning of the rear of front folding units, preferably to the initial distance which can be used at the supporting station 77.
  • the top panel folder 86 with rods 96-99 described here can also be used in the folding system of Fig. 1 in which the box remains stationary during folding not only to fold the top panels but also for discharging the box from the supporting station 7 thereof.
  • the seal applicator 85 comprising seal applicator units 85A, 85B which are displaceable in height and in transverse distance away from and towards each other has applied the sealing tape 74 (Fig. 2G) around the box and the sealed box 67' is discharged via a discharge conveyor 100.
  • the control unit 62 controls the displacement of the seal applicator units 85A, 85B based on the data indicative for the measured length, width and height dimensions such that the tape is applied on the box 67' at the correct level.
  • a system 61 ' for automatically forming and for packaging items therein, in this embodiment simultaneously with the formation of packaging boxes as described with reference to Fig.s 4A-4M is shown in which the scale of drawing is more realistic.
  • the control unit of this system 61 ' can be configured to either fold the box during transport of the blank material as described with reference to Fig. 4 or to fold the box while the blank material remains stationary. In the latter case the top folding units 94, 95 are displaceable to above the rear folding units 80, 81.
  • the input conveyor is left out in Fig. 5A so that the blank forming station 72 with the blank forming apparatus 73 is visible as well as the feeding conveyor 76.
  • the slanting belt 91 can already be raised by the raiser 90 to support the top panel after the moment front suction cups of folding elements 82, 83 have been activated.
  • the system 61 is quite compact in length and the top folding units 94, 95 of the top panel folder 86 can be displaced to a position above the rear folding units 80, 81. As mentioned above the system 61 ' can thus operate in two operation modes under control of the control unit 62.
  • the rods 96-99 of the top folding units are activated to engage the box and the top panel folder 86 is moved from the supporting station to the sealing station to discharge the folded box from the supporting station into the sealing station. Activation of the top folding units can take place during movement of the top panel folder towards the sealing station.
  • FIG. 5B which has already been described above, a top view of Fig. 5A seen from above the top panel folder is shown.
  • the top panel folder has been left out as well as the additional supports 92A-92C to more clearly depict the connection of the front and rear folding units 80-83 which are coupled by means of sliding rods 88A, 88B and 89A, 89B such that by means of a single transverse motor 87 relative transverse 5 displacement of the folding units is allowed by means of a sliding engagement of the sliding rods or bars and the connection pieces of the folding units.
  • Fig. 5B shows that the last downstream input sub-conveyor 96 and the transfer strip 71 are positioned closely adjacent to each other as is also indicated in Fig. 7.
  • Fig.s 6A-6F the blank forming apparatus 73 of the system 61 will be described in more detail. Since this blank forming apparatus 73 and the control unit 62 can be configured for performing cutting and creasing blank material into a custom sized blank based on the data indicative for the measured dimensions during feeding of the blank material in feeding direction the production capacity of the system 61 can be increased.
  • the blank forming apparatus 73 is in particular suitable to be used in said system 61 , it might also be advantageously used in combination with the system 1 as described with reference to Fig. 1 and be controlled by the control unit 2 thereof.
  • Fig. 6A a top view in perspective of the blank forming apparatus 73 is shown in which blank material 101 is fed through the blank forming apparatus to indicate the position of the constituting parts relative to each other more clearly.
  • Fig. 6B the same view is shown, but now with the blank material left out to ore clearly show the lower parts of the blank forming apparatus 73.
  • the blank forming apparatus 73 comprises a single transverse cutter 102 for cutting blank material to length for forming a custom sized blank.
  • the single transverse cutter 102 is suspended to be movable along a line or guide 103 which is positioned at an angle with respect to the feeding direction F of the blank material 101.
  • the control unit 2, 62 is configured to control the movement of the single transverse cutter 102 by means of motor TCM along the line 103 and the feeding speed of the feeding conveyor such that the cutter 102 forms a cutting line in the blank material which is transverse to the feeding direction, i.e. which is perpendicular to the side edge of the blank material.
  • the single transverse cutter 102 can comprise a rotatable knife 104 and a counter roller 105.
  • the blank forming apparatus can comprise a single longitudinal cutter for cutting the custom sized blank to width
  • the blank forming apparatus 73 shown in Fig. 6A comprises a pair of longitudinal cutters 106, 107 for cutting the blank material to width for forming the custom sized blank.
  • the transverse distance between the pair of longitudinal cutters 106, 107 is adjustable by means of a motor LCM under control of the control unit 2, 62 based on the data indicative for the measured width dimension.
  • the longitudinal cutters 106, 107 can each comprise a rotatable knife and a counter roller.
  • the blank forming apparatus 73 furthermore comprises a single transverse score applicator 108 for applying transverse score lines as transverse folding lines to the blank material 101 between respective panels.
  • the transverse score applicator 108 comprises an upper transverse score roller 109 with score ridges 110 and a lower counter score roller 111 optionally also provided with score ridges.
  • a score ridge can be formed of a single ridge or multiple ridges closely spaced next to each other in order to form multiple score lines closely spaced next to each other.
  • Rotation of the rollers 109, 111 is effected by means of a motor TSM under control of the control unit 2, 62 based on data indicative for the measured dimensions and the feeding speed of the blank material.
  • a pair of longitudinal score applicators 112, 113 (see also Fig.s 6C- 6F) is provided for applying longitudinal score lines as longitudinal folding lines to the blank material 101.
  • the longitudinal score applicators 112, 113 are suspended to be displaceable downwards by means of a motor LSM under control of the control unit 2, 62.
  • the transverse distance between the longitudinal score applicators 112, 113 is adjustable by means of a motor LSTM under control of the control unit 2, 62 based on the data indicative of the measured width.
  • Each longitudinal score applicator comprises an upper rotatable element 113A and a lower rotating counter element 113B (see Fig. 6E).
  • Each of the pair of upper longitudinal score applicators 112, 113 comprises a coupling 114, 115 for realizing a mechanically coupling to a respective cut-out knife 116, 117.
  • the cut-out knives 116, 117 belong to a cutting-out device 120 which is configured to displace the cut-out knives 116, 117 downwards for forming the cut-outs between corner panels and adjoining side panels of the custom sized blank. Due to the couplings 114, 115 the transverse distance between the opposite cut-out knives 116, 117 is adjustable simultaneously with the adjustment of the longitudinal score applicators 112, 113 and thus this transverse distance is adjustable based on the data indicative for the measured width.
  • the couplings 114, 1 15 are configured for allowing a vertical movement of a cut-out knife 116, 117 relative to a respective longitudinal score applicator 112, 113, which is realized in the embodiment shown in Fig. 6 in that the couplings 114, 115 are pivotally mounted around pivot axes 118, 119 which lie in each other's extension.
  • the couplings 114, 115 are in this embodiment formed by an A-frame.
  • Each cut-out knife 116, 117 comprises an extension 121 (only shown for cut-out knife 117 in Fig. 6E) which is in engagement with a lower transverse guide 123, 124. Due to the couplings 114, 115 and to the lower transverse guides 123, 24 the frame for mounting the cut-out knives 116, 117 can be realized by means of a light-weight construction. This can furthermore be promoted by providing cut-out knives with an extremely effective cutting operation. In the embodiment shown, this cutting operation is surprisingly effective in case the angle A (Fig.
  • the cutting-out device 120 is suspended so as to be displaceable from an inactive position in which the cut-out knives 116, 117 are raised (Fig. 6D) to an active position downstream of the inactive position synchronously with the feeding speed of the blank material in feeding direction. In this active position the cut-out knives 116, 117 are still raised but are present at a position in which they can be lowered at a relatively high vertical speed such that they can be almost instantly positioned into the cutting position as shown in Fig. 6E.
  • the cut-out knives can in addition move in feeding direction.
  • the control unit 2, 62 and the cutting-out device 120 are configured such that the active position, the vertical lowering speed and the optional horizontal speed are such that the cut-outs are provided in the correct position on the blank material, i.e. in line with respective transverse folding lines to be applied by the transverse score line applicator 109.
  • the cutting-out device comprises a pair of cam discs 128, 129 each cooperating with cam followers 131 (shown in Fig. 6F for cam disc 129) of a respective cut-out knife 117.
  • Each cam disc 129 comprises an outer surface 132 with an outer cam track 133 and an inner surface 134 provided with an inner cam track 135.
  • the outer cam track 133 controls the movement of the cutting-out device from the inactive position to the active position and vice versa in feeding direction and the inner cam track 135 controls the downward and upward movement of the cut-out knives.
  • the outer cam track 133 is configured such that the cut-out knives 116, 117 are displaceable in a direction opposite the feeding direction from the active position to the inactive position at a higher speed than the feeding speed of the blank material, which ensures a high production capacity of the blank forming apparatus since the feeding speed of blank material can be increased while it is still possible to provide the necessary plurality of cut- outs with only one cutting-out device 120.
  • the cam discs 128, 129 are driven by a cam disc motor CDM (Fig. 6D) under control of the control unit 2, 62.
  • the blank forming apparatus can be used in a particularly advantageous manner for, under control of the control unit, cutting and creasing blank material into a custom sized blank having a rectangular bottom panel having a center line substantially parallel to the feeding direction, rectangular side panels and rectangular end panels joined to the bottom panel, rectangular corner panels joined to the end panels, a rectangular top panel joined to one of the end panels, rectangular top side panels joined to the top panel, a
  • Fig. 8 a view in perspective of the top panel folder 86 is shown.
  • the top folding unit 95 is shown in more detail in Fig. 9, and it will be clear that the corresponding top folding unit 94 is formed analogously, but with the side and end folding flaps interchanged.
  • the top pair of folding units 94, 95 are suspended to be displaceable along a guide 136 with respect to one another under control of the control unit 2, 62 for adjusting a top transverse distance there between based on the data indicative for the measured width dimension by means of a motor 137 and can be lowered to come into contact with respective corners of the top panel 50 and raised out of contact therewith by means of a motor 138 under control of the control unit.
  • the top folding unit 95 is provided with a controllable end panel (53) folding flap 139 and a controllable side panel (52) folding flap 140 and a controllable initiator 141 for initiating the folding of a corner panel (54).
  • the top folding units in this embodiment do not comprise gripping elements or suction cups but are provided with a controllable, vertically displaceable pushing element 142 for pushing down a respective corner of the top panel onto the upstanding side panels.
  • the top folding units also comprise gripping elements.
  • the initiator is lowered into the position indicated by reference number 141' for initiating downward folding of the top corner panel 54.
  • the side panel folding flap 140 is activated (Fig. 9B) and shortly thereafter the end panel folding flap 139 (Fig 9C) to fold down the top side panels 52 and a top end panel 53 as indicated in Fig.s 2E, 2F.
  • the top folding units can be moved a little distance towards each other to ensure correct folding.
  • top folding units 94, 95 are furthermore provided with controllable rods 96, 97 and 98, 99 which are activated, i.e. lowered, under control of the control unit 62 after the box is completely folded.
  • the rods 96 and 97 engage the side surfaces of the box, whereas the rods 98, 99 engage the rear surface of the box, i.e. the surface.
  • the rods 96-99 keep the box 67' in shape and prevent recoiling of the panels of the blank and can be used to transport the box.
  • the system may comprise further devices, preferably controlled by the control unit, such as for example: a device for supplying filling material, e.g. shredded paperboard, chips, filling bags or foam, into the box, for filling up possible empty spaces inside the box; an address printer for printing addresses directly onto the box or on an address sticker, which address sticker is adhered to the box by means of a sticker module; a scale for weighing the box including the items, a franking unit.
  • a wrapping unit may be present to wrap the box into for example gift paper.
  • an applicator for applying tape to the box to seal it it is possible to use a glue applicator which applies glue to appropriate panels for sealing the box.
  • sealing the box is in alternative embodiments performed by strapping, stapling or poly- wrapping.
  • the top panel folder comprises at least one blowing unit, in the embodiment shown two blowing units 150 and 152, which are arranged in each top panel guides 93 for assisting the folding of the top panel 50 towards a position, in which it is positioned over and at least substantially parallel to the rectangular bottom panel 41.
  • the control unit is configured for operating said the at least one blowing unit at least when a top panel 50 is about to make contact with the top panel guides 93.
  • the blowing units 150 and 152 are nozzles connected via respective ducts to a source of pressurized air. By blowing air towards the top panel, guidance of the top panel when folding it can be improved and impacts on the cardboard can be reduced to enable a smoother panel movement.
  • top panel guides may be provided with rollers as will be explained in conjunction with Fig. 12.
  • Fig. 11 shows an embodiment, in which the top panel folder comprises at least one additional unit for keeping the top panel flat after it has passed the top panel guides 93.
  • this additional element comprises a support 154, which in this embodiment is attached to top panel guide 93, and a skid 156 suspended on said support 154 via springs 158.
  • This arrangement is thus provided approximately at the intended height of a box folded by the aid of the top panel guides 93 and either keeps a folded top panel flat and substantially parallel to the bottom panel or presses top panel in such position in case until the top part of the box 67' is affixed, e.g. glued, taped, bound or stitched to the bottom part.
  • the ends of the skid 156 are slightly curved upwards in a direction facing away from a top panel.
  • the ends may also have other shapes and may for example be chamfered.
  • springs 158 other suitable suspension means may be foreseen such as a soft layer or flexible elements between the skid and the support 154.
  • Fig. 12A, 12B, 12C and 12D show a further embodiment of the invention, in which the top panel folder comprises a driven arrangement to correct accidental misalignment or mis-positioning of the top panel 50.
  • the top panel folder comprises a driven arrangement to correct accidental misalignment or mis-positioning of the top panel 50.
  • a blank comprises an unwanted fold (line) 160
  • the top panel 50 may not be put or remain in the desired position (in parallel and above the bottom panel) just by passing the top panel guide 93.
  • folds and fold lines are marked in Fig.s 12A to 2D by circles.
  • a driving arrangement 162 may be foreseen.
  • the arrangement 162 may then be lowered gradually into a position where its bottom is approximately at the intended height of the box.
  • Said tip 164 of the top panel guide 93 is preferably smooth or comprises at least one rolling element to enable smooth movement over the top panel 50.
  • the driving arrangement 162 is driven, so that a driven element 166 such as a belt or rollers will urge any cardboard to straighten towards the free end 168 of the top end panel.
  • the driven element 166 has a surface with a relatively high grip on the cardboard, such as rubber and/or a profile.
  • the driving of the driven arrangement 162 may be adapted depending on the position of the driven arrangement with respect to the intended or real position of the box. After the driven arrangement 162 has reached the intended level of the top of the box, it can be used to maintain correct alignment of the top of the box at least until the box is completely closed, and/or guide the box during further processing, e.g. transporting towards a sealing unit.
  • the tip 164 of the top panel guide 93 may be provided with at least one rolling element 170, of which the circumferential speed is forced to be such that the relative speed at the contact area with the top panel 50 equals zero, with respect to the speed of the bottom panel, at least during the relative movement of the top panel guide 93 with respect to the box.
  • the rolling element of the tip 164 has a surface with a relatively high grip on the cardboard. If the tip does not slip, it can be prevented that the top panel may move into an undesired direction during relative movement of the top panel guide 93 and the box to close the box.
  • line 172 indicates the intended height of the box, being the intended level of the top panel with respect to the bottom of the box.
  • the speed v C j rcum f er ence of the rolling element 170 at the circumferential surface of said rolling element 170, at the intended contact point with the top panel of the box, should equal the relative speed Vfj p between the tip 93 and the box 67' after the rolling element passes line 174, which indicates the intended front end of the box.
  • the speed at the contact point with respect to the bottom of the box will then be zero.
  • the rolling element will adapt the same speed as it would have when moving over a solid box (as shown schematically in Fig. 13B). This forces the top panel to follow the rolling element and limit the chance of unintended misalignment or mis-positioning.
  • the rolling element may be driven by any suitable driving source, including a mechanical connection with the frame.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Making Paper Articles (AREA)

Abstract

L'invention concerne un procédé et un système de mise en forme automatique de boîtes d'emballage à partir d'une découpe présentant un panneau inférieur rectangulaire, des panneaux de côté et d'extrémité rectangulaires et un panneau supérieur rectangulaire. Les panneaux de côté et d'extrémité de la découpe sont pliés vers le haut dans une position sensiblement verticale et le panneau supérieur est progressivement soulevé. Une plieuse de panneau supérieur est fourni, qui est positionné à un niveau supérieur de plieuse au-dessus du niveau défini par le panneau inférieur. La plieuse de panneau supérieur est déplacé dans une direction pour plier le panneau supérieur en une position qui est sensiblement parallèle au panneau inférieur rectangulaire.
PCT/IB2014/000342 2013-01-29 2014-01-29 Procédé et système de mise en forme automatique de boîtes d'emballage WO2014118631A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
PCT/EP2013/051698 WO2014117818A1 (fr) 2013-01-29 2013-01-29 Procédé et système de formation automatique de boîtes d'emballage
EPPCT/EP2013/051698 2013-01-29
EPEP13169286.5 2013-05-24
EP13169286 2013-05-24

Publications (1)

Publication Number Publication Date
WO2014118631A1 true WO2014118631A1 (fr) 2014-08-07

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016157089A1 (fr) * 2015-04-01 2016-10-06 Ponti Lorenzo Système et procédé pour former un paquet sur mesure
WO2021018952A1 (fr) * 2019-07-30 2021-02-04 Anheuser-Busch Inbev S.A. Appareil d'emballage pour des emballages secondaires
EP3842350A1 (fr) * 2019-12-26 2021-06-30 Anheuser-Busch InBev S.A. Appareil d'emballage pour emballages secondaires
US11713147B2 (en) 2019-07-30 2023-08-01 Anheuser-Busch Inbev S.A. Article picking and treating apparatus

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US1772785A (en) * 1925-10-26 1930-08-12 Hoague Sprague Corp Art of working cardboard and similar material
FR2654066A1 (fr) * 1989-11-07 1991-05-10 Bello Martino Appareil pour positionner des alveoles receptrices de fruits et legumes dans des caisses en carton selon le principe de fermeture des caisses dites "caisses americaines" et le procede de positionnement des alveoles dans les caisses.
US5660262A (en) * 1995-01-13 1997-08-26 Kliklok Corporation High speed carton feeding/turning system
DE19636262A1 (de) * 1996-09-06 1998-03-12 Ligmatech Maschb Gmbh Faltmaschine und Verfahren zum automatischen Falten einer Faltschachtel
EP0983940A1 (fr) * 1998-09-03 2000-03-08 Winkler + Dünnebier Aktiengesellschaft Dispositif pour emballer des objets ou des piles
US6170231B1 (en) 1998-10-15 2001-01-09 R. R. Donnelley & Sons Company Apparatus for bulk cartoning of books
US20070084744A1 (en) * 2005-10-17 2007-04-19 Paul Appelbaum Apparatus and method for packaging articles in clear plastic packages

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Publication number Priority date Publication date Assignee Title
US1772785A (en) * 1925-10-26 1930-08-12 Hoague Sprague Corp Art of working cardboard and similar material
FR2654066A1 (fr) * 1989-11-07 1991-05-10 Bello Martino Appareil pour positionner des alveoles receptrices de fruits et legumes dans des caisses en carton selon le principe de fermeture des caisses dites "caisses americaines" et le procede de positionnement des alveoles dans les caisses.
US5660262A (en) * 1995-01-13 1997-08-26 Kliklok Corporation High speed carton feeding/turning system
DE19636262A1 (de) * 1996-09-06 1998-03-12 Ligmatech Maschb Gmbh Faltmaschine und Verfahren zum automatischen Falten einer Faltschachtel
EP0983940A1 (fr) * 1998-09-03 2000-03-08 Winkler + Dünnebier Aktiengesellschaft Dispositif pour emballer des objets ou des piles
US6170231B1 (en) 1998-10-15 2001-01-09 R. R. Donnelley & Sons Company Apparatus for bulk cartoning of books
US20070084744A1 (en) * 2005-10-17 2007-04-19 Paul Appelbaum Apparatus and method for packaging articles in clear plastic packages

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016157089A1 (fr) * 2015-04-01 2016-10-06 Ponti Lorenzo Système et procédé pour former un paquet sur mesure
CN107531336A (zh) * 2015-04-01 2018-01-02 洛伦佐·蓬蒂 用于形成自定义包装的系统和方法
CN107531336B (zh) * 2015-04-01 2019-10-25 洛伦佐·蓬蒂 用于形成自定义包装的系统和方法
US10793300B2 (en) 2015-04-01 2020-10-06 Lorenzo Ponti System and method for forming a custom-sized package
AU2016241566B2 (en) * 2015-04-01 2021-01-21 C.M.C. S.P.A. System and method for forming a custom-sized package
WO2021018952A1 (fr) * 2019-07-30 2021-02-04 Anheuser-Busch Inbev S.A. Appareil d'emballage pour des emballages secondaires
CN114466796A (zh) * 2019-07-30 2022-05-10 安海斯-布希英博有限公司 用于二级包装的包装设备
US11713147B2 (en) 2019-07-30 2023-08-01 Anheuser-Busch Inbev S.A. Article picking and treating apparatus
CN114466796B (zh) * 2019-07-30 2024-04-16 安海斯-布希英博有限公司 用于二级包装的包装设备
EP3842350A1 (fr) * 2019-12-26 2021-06-30 Anheuser-Busch InBev S.A. Appareil d'emballage pour emballages secondaires

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