WO2022067452A1

WO2022067452A1 - Machine and method for the automatic assembly of collapsible boxes

Info

Publication number: WO2022067452A1
Application number: PCT/CL2021/050093
Authority: WO
Inventors: Pedro Chinni
Original assignee: Wenco S.A.
Priority date: 2020-09-29
Filing date: 2021-09-29
Publication date: 2022-04-07
Also published as: CL2020002515A1

Abstract

A machine and method for assembling plastic boxes with collapsible walls, said machine comprising a dispensing module (20) for receiving and guiding a pile of boxes (1) in an unfolded configuration; a feed module (30) for releasing a box (1) from the pile of boxes in the dispensing module (20); a distribution module (40) comprising at least two box carriers (41) disposed on a rotating structure, each box carrier (41) comprising a central opening surrounded by trays (42) for holding a box (1); and an assembly module (50) comprising a punch (51) connected to an ascending and descending arm (52).

Description

MACHINE AND METHOD FOR THE AUTOMATED ASSEMBLY OF FOLDING BOXES

DESCRIPTIVE MEMORY

[0001] The present invention is aimed at the technical field of automation. In particular, it is related to the machines for the automated assembly of folding boxes that are used in the agricultural industry for the storage and transport of horticultural products, in order to reduce the time of assembly of boxes and the use of human resources for such purposes. .

BACKGROUND OF THE INVENTION

[0002] In the packaging and transport industry, especially in that oriented to the handling of horticultural products, the use of containers or boxes made of plastic material has been increasingly consolidated, which have gradually taken market share from cardboard , especially for its good resistive properties. These types of boxes are usually manufactured using the plastic injection technique and can be classified into two main types.

[0003] A first type of plastic boxes are called monobloc or monoblock by its name in English. These boxes are built in one piece and with their walls fully erect so that when they leave the manufacturing mold they are ready for use.

[0004] A second type of plastic boxes are the so-called collapsible or collapsible boxes, which are essentially composed of a base and four walls that fold down independently of said base. Collapsible boxes can also be made in one piece, but have the advantage that, as they have collapsible walls, they can be arranged in an open or folded configuration (with the walls oriented parallel to the base), so that the height to be obtained in said configuration is significantly less than in a monobloc type. Some examples of collapsible plastic boxes are disclosed in patents CL 52101, CL 56058, CL 56160, CL 525, CL 58267, CL 564, CL 599 or CL 680.

[0005] Once the boxes are manufactured, they are usually stacked and transported on pallets to the place of destination. It is precisely in this operation where folding boxes outperform monobloc boxes, since, when stacked and transported in a folded arrangement, the volume they use compared to the former is much lower, thus allowing the transport of a greater number of units. and therefore reduce the costs associated with transportation and use of spaces. However, the foregoing requires that the boxes must be assembled at the place of destination for later use as a means of storage or packaging. [0006] This assembly operation can be carried out manually, which implies that people, by means of their hands, unfold the walls, lowering them in a vertical position with respect to the base and fixing them to each other by means of connection elements that the walls have specifically for said purpose, such as those disclosed in patent CL 56058.

[0007] Alternatively, the assembly operation can also be carried out by means of automated equipment, which consist of machines or robots configured to unfold the walls sequentially, thus avoiding the use of human resources for this purpose and allowing the assembly of boxes by hand. a much higher rate.

[0008] An example of a box assembly machine is that disclosed in document US 2008127613, which is composed of a loader to hold a stack of folded boxes, an assembly mechanism to assemble a box contained in the loader, a mechanism transfer mechanism to transfer the box to the cocking mechanism and a dispensing mechanism to distribute the box from the loader to the transfer mechanism. The cocking mechanism includes wall lifting mechanisms which in turn comprise clamping members, actuators and pivoting arms.

[0009] Document EP 12720219 discloses a method and machine for opening walls of a box arranged on a stack of closed boxes comprising means for lifting the stack to an opening station, means for opening a first pair of opposite walls, opening means for a second pair of opposite walls, reciprocal locking means between at least two adjacent walls and comprising a central actuation body that carries, on two opposite sides, two horizontal arms that support the corresponding operation boxes and that are each provided with respective removable means selectively movable in and out of the corresponding operation box, each removable means being movable in essentially parallel but opposite directions, when referring to the two opposite operation boxes.

[0010] Other examples of machines and methods for the automatic opening of plastic boxes are also disclosed in documents CL 201601736 and CL 201600474.

[0011] A common aspect that all the aforementioned automated mechanisms of the state of the art have is that they are designed exclusively to assemble hinged boxes, that is, they have a hinge element with a pin (or similar element) as a means of joining between the bottom of the box and each of its walls, or a folding mechanism.

[0012] Hinged boxes are usually stacked in a folded configuration, that is, with their walls folded over the bottom of the box so that prior to packaging they require a folding stage, which can be done manually or automated . Then, at the point of assembly they must be inserted into the assembly machine precisely in a folded configuration, as disclosed in the aforementioned state of the art documents. In all of them, the means that unfold the walls consist of gripping elements or articulated arms configured to raise, in a first step, a pair of opposite walls of the box and in a second step, the other pair of opposite walls. However, the use of articulated arms involves no minor challenges in terms of synchronization, adjustment, operation and space, having to have four units (one for each wall) and their respective actuator and locking mechanisms, being also a highly flexible solution. expensive. On the other hand, the deployment of the walls in two steps has the disadvantage that it requires more time for assembly compared to an assembly in a single step.

[0013] In this way, there is no solution in the state of the art for assembling plastic boxes made in one piece, that is, that do not have hinges between the walls and the bottom. This type of boxes are usually built with a lower thickness and at a much lower cost than hinged boxes, since they are designed for a single use, such as for the transport of export goods where at the destination point the box is not reused, but usually recycled.

[0014] Therefore, a first objective of the present invention is to provide a solution for the automated assembly of folding boxes built in a single piece.

[0015] A second objective of the present invention is to provide a solution for the automated assembly of folding boxes, which requires fewer elements and stages for its assembly, resulting in a simpler and faster process than those of the state of the art. and with minimal or no human intervention.

DESCRIPTION OF THE INVENTION

[0016] According to a first aspect of the invention, a machine for assembling plastic boxes with folding walls is proposed, which comprises:

- a metering module for receiving and guiding a stack of boxes in an unfolded configuration;

- a feeder module for releasing a box from the stack of boxes of the dosing module;

- a distribution module comprising at least two box carriers arranged in a rotating structure, each box carrier comprising a central opening surrounded by trays for holding a box; and

- an assembly module comprising a punch connected to an ascending and descending arm. [0017] The combination of the aforementioned modules allows the assembly of plastic boxes manufactured in a single piece through a quick and significantly simpler operation than with state-of-the-art machines.

[0018] A first advantage in this sense is obtained thanks to the use of the dosing module, which allows having a stack of boxes that are then successively fed into the machine for assembly. This prevents an operator from constantly loading the machine with unit boxes and therefore allows volume feeding, which can be done manually or automatically but does not depend on the speed of an operator and therefore avoids unnecessary stops. in the assembly process.

[0019] Secondly, thanks to the rotating distribution module in combination with the punch assembly module, a very efficient solution is obtained for the assembly of the walls of the box, since the assembly operation is achieved in a single step , unlike state-of-the-art machines that use two steps to assemble each pair of walls and therefore a longer assembly time. In addition, by means of the puncture assembly concept proposed by the present invention, the use of mechanical arms that act in conjunction with claws for the assembly of the walls is avoided, thus providing a simpler mechanism, with a smaller number of elements and that Therefore, it requires less maintenance and investment.

[0020] According to the present invention, the punch of the reinforcement module has a straight base and vertical walls. For their part, the trays of the box carriers are inclined. Advantageously, this configuration allows the trays to act as anvils and when the punch acts on the bottom of the box, their inclination is such that it allows the walls to verticalize in a sequence that allows the joining of their tongue-and-groove connection means that They are the ones that usually have plastic boxes made in one piece.

[0021] According to a preferred embodiment, the machine comprises a transport module with a conveyor belt that receives an assembled box from the assembly module. In addition, the transport module includes an assembly sensor to automatically expel defective boxes or boxes that were not properly assembled in the assembly module from the machine. On the other hand, the transport module also comprises a separating guide for the straps of the assembled box, which allows said straps to be correctly positioned during the subsequent stage of stacking the assembled boxes.

[0022] According to a preferred embodiment, the machine further comprises a stacking module that receives boxes from the transport module, said stacking module comprising a stacker base connected to an elevator, vertical stacking guides and a stacking element , which together allow the automatic formation of a stack of assembled boxes downstream of the assembly module. The stacking module further comprises an ejector for removing a stack of boxes.

[0023] According to a preferred embodiment, the machine further comprises an input module with a conveyor belt to receive boxes upstream of the dosing module and an output module with a third conveyor belt to remove a stack of boxes from a loading module. piled up.

[0024] According to a second aspect of the invention, a method for assembling plastic boxes with walls is also proposed, which comprises the steps of: a) stacking boxes in an unfolded configuration inside a dosing module; b) releasing a box from a stack of boxes in the dosing module by means of a feeder module; c) receive the box released by the dosing module in a box carrier of a rotating structure of a distribution module, said carrier being in a first position and the walls of the box resting on trays, while the bottom of the box rests on a central opening of said box carrier; d) rotating the distribution module until the box carrier holding the box is in a second position; e) lowering a punch connected to an arm of an assembly module and pressing the bottom of the box, moving it through the central opening and at the same time lifting the walls of the box, leaving the latter in an armed configuration; and f) repeating the method from step b) onwards.

[0025] According to a preferred embodiment, the method comprises receiving on a conveyor belt of a transport module, the armed box that comes out from the central opening of the box carrier and verifying by means of an armed sensor (61) that it is box (1) received in the transport module is well assembled or is not defective. Thus, it comprises ejecting the box from the machine if the assembly sensor detects that the box is not properly assembled or is defective.

[0026] Otherwise, the method comprises transporting the assembled box by means of the conveyor belt to a stacking module to assemble a stack of boxes. Next, it comprises receiving from the stacking module, a stack of assembled boxes in an output module comprising a third conveyor belt.

[0027] According to a first embodiment, the proposed method comprises prior to step a), receiving stacks of boxes in an input module consisting of a first conveyor belt, where the transfer of the boxes from the input module to the dosing module is done manually.

[0028] According to a second modality, the transfer of the boxes from the input module to the dosing module is carried out automatically.

BRIEF DESCRIPTION OF THE FIGURES

[0029] As part of the application, the following representative figures of the invention are presented, which show preferred configurations thereof and, therefore, should not be considered as limiting the definition of the claimed matter.

- Figure 1 illustrates an exemplary and suitable folding plastic box to be assembled by the machine and method of the present invention.

- Figure 2 illustrates a general perspective view of the box assembly machine of the present invention.

- Figure 3 illustrates a view of the right profile of the box assembly machine of the present invention.

- Figure 4 illustrates a top view of the box assembly machine of the present invention.

- Figure 5 illustrates a rear elevation view of the box assembly machine of the present invention.

- Figure 6 illustrates a view of the right profile of the box assembly machine of the present invention.

DETAILED DESCRIPTION OF THE FIGURES

[0030] According to Figure 1 and by way of example, a collapsible plastic box 1 manufactured by plastic injection and in an assembled configuration is shown. The box comprises a bottom 2, a pair of larger walls 3 and a pair of smaller walls 4, said walls being configured to fold over the bottom 2 through fold lines 5 and being joined together by means of tongue-and-groove connection means 6 arranged in its lateral ends. Furthermore, the box may comprise tension braces 7 attached to the upper ends of the larger walls 3.

[0031] Figure 2 illustrates a general view of the assembly machine of the present invention which consists of a series of modules that will be described in detail and with reference to the rest of the figures.

[0032] First of all, the machine comprises an input module 10 consisting of a first conveyor belt and consisting of a free belt sensor at one of its ends 11. The conveyor belt of the input module 10 is configured to receive stacks of plastic boxes in a folded configuration (as stacked on a pallet) and which are transported automatically to end 11 when the sensor detects that there is space available on the tape. From that point, the boxes are transferred to a dosing module 20 of the machine.

[0033] According to a first modality, the transfer of the boxes from the input module to the dosing module 20 is carried out manually, for example, through an operator located in a transfer zone 12 that is between the input module 10 and the dosing module 20. In said transfer zone 12, the operator takes a box from the first conveyor belt of the input module 10 and deposits it in the dosing module 20 with the walls of the box in an extended position or unfolded. According to a preferred configuration, the dosing module comprises a magazine rack (not illustrated) that may consist of support bars located at the entrance 13 of the dosing module 20 to pre-stack boxes with their walls unfolded before inserting them into the dosing module 20 forming a stack of boxes.

[0034] According to a second modality, the transfer operation of boxes from the input module 10 to the dosing module 20 is carried out automatically, for example, through the use of conveyor belts, robot arms or any other means appropriate. In this mode, the machine also comprises additional means for automatically unfolding the walls of the boxes from their folded condition, said means being located, for example, before the entry of the boxes into the input module 10 or inside it, and even between the module input 10 and dosing module 20.

[0035] Figure 3 illustrates in more detail the metering module 20, which consists of stacking guides 21 for receiving and vertically guiding a stack of boxes in an unfolded configuration. The boxes 1 located in the dosing module 20 are retained by means of a retention mechanism located in the lower part of the stacking guides 21, which preferably consists of a set of heads operated by cylinders which in turn are commanded by position sensors. Furthermore, under the dosing module 20 there is a feeder module 30 configured to release the first box 1 located in the dosing module 20. Said feeder module 30 is operated by means of retaining cylinders and position sensors.

[0036] When the feeder module 30 releases the first box 1 from the dosing module 20, it is received in a distribution module 40, which will be described in more detail with reference to Figure 4. According to it, the distribution module 40 consists of a structure comprising two box carriers 41 arranged parallel therein. Each box carrier 41 comprises a central opening surrounded by four trays 42. The latter are configured to support each wall of the unfolded box 1, so that the bottom of the box is just above the central opening. The structure of the distribution and assembly module is connected to a rotator located in the center 43 of its longitudinal axis, said rotator consisting on a pneumatic actuator configured to rotate the distribution and assembly module through an angle of 180°.

[0037] In this way and as shown in Figure 4, when the box 1 is released from the feeder module, it falls on a box carrier 41 located in a position I, leaving the walls of the box resting on each one of the trays 32. Next, the structure is rotated by 180° by means of the rotator passing the box 1 from position I to position II.

[0038] On the tray 42 located in position II and according to Figures 3 and 4, there is an assembly module 50 which consists of a punch 51 with a straight base and vertical walls connected to an ascending and descending arm 52. As can be seen in Figure 3, when a box is located in the box carrier located under the assembly module 50, the arm 52 descends vertically in the direction a and the punch that is aligned with the central opening of the carrier 41 ( Fig. 4) presses the bottom of the box 1 moving it through the opening of said carrier and at the same time causing the walls of the box to rise and rest against the walls of the punch 41. By means of this movement, the hook is produced of the connection means 6 of the box 1 illustrated in Figure 1. This is due to the fact that the four trays 42 of the carriers 41 that support each wall of the box act as anvils and have different inclinations such that they allow, by activating the punch 51, the walls of the box that have the male elements of said connection means are closed on the walls that have the respective female elements, thus achieving the closure and assembly sequence from the box.

[0039] After the assembly operation, the box carrier that did not contain the box that was armed, is in position I ready to receive a new box from the feeder module 30 and be moved to position II to be carried out a new activation of the punch 51. This operation is repeated until all the boxes of the stack located in the dosing module 20 are exhausted.

[0040] As seen in Figures 3 and 5, the assembled box 1 that passes through the central opening of the box carrier after actuation of the punch, descends to a second level with respect to that where the distribution module 40 is located, specifically to a transport module 60 comprising a second conveyor belt 61 which receives the box and transports it in a first direction Di to a stacking module 70.

[0041] According to Figure 5, the transport module 60 comprises an assembly sensor 61 which detects that the box 1 that descends on the second conveyor belt from the assembly module is well armed before being transported to the module stacking 70. Otherwise, the sensor sends a signal so that the conveyor belt reverses the direction of transport and rejects box 1, sending it in a second direction D2 out of the machine. [0042] According to a preferred embodiment, the arming sensor 61 consists of a laser configured to detect the alignment of the box walls, particularly that the walls are correctly upright at 90° with respect to the base. If the sensor detects otherwise, it means that the box was not properly assembled or that it has defective wall connection means and therefore must be rejected.

[0043] The stacking module 70 is therefore fed with boxes 1 through the transport module 60. The latter, and prior to the box entering the stacking module 70, comprises a separating guide 63 that what it does is keep the straps box tensioners 7 open to ensure that they remain on the outside of the stack of boxes and do not interfere with its formation. For its part, the stacking module 70 comprises a stacker base 71 to receive a box 1 and vertical stacking guides 72 to align the corners of the boxes 1 during stacking.

[0044] Continuing with Figure 5, the stacker base 71 is connected to an elevator 73 so that the box 1 that is received by the stacker base 71 is raised to a second box position 1' where it is retained by a stacking element 74 (FIG. 6), such as a guide cylinder. Next, the stacker base 71 returns to its initial position to receive a new box and take it to the second box position 1', moving the box that was previously in that position to a third box position 1" and so on until Form a stack with the desired number of boxes. The stacking module further comprises a series of sensors to determine the stacking position of the boxes, as well as the position of the stacking element 74 and the box at the maximum stacking height.

[0045] According to Figure 6, the machine comprises an ejector 72 that is responsible for removing the stack of boxes from the stacking module when the assembly of the stack with the desired number of boxes is completed. The ejector 72 can be made up of a stack ejection cylinder commanded by a sensor and comprising an ejection gripper that removes the stack by pushing it through the lower located box 1 towards an output module 80. Finally, the output module 80 it consists of a third conveyor belt 81 that receives the stacks of boxes from the stacking module 70 and transports them to an exit point of the machine.

[0046] The machine of the present invention further comprises a control cabinet 90 inside which an operator control panel is arranged. Said control panel includes all the electronic means that control the operation of the machine and allow its programming, on, off, etc. In addition, according to the illustrated embodiment, the machine comprises protection means 90 consisting of perimeter covers to protect the elements of the machine, access doors for operators and maintenance equipment.

Claims

1. A machine for assembling plastic boxes with folding walls, CHARACTERIZED because it includes:

- a metering module (20) for receiving and guiding a stack of boxes (1) in an unfolded configuration;

- a feeder module (30) to release a box (1) from the stack of boxes of the dosing module (20);

- a distribution module (40) comprising at least two box carriers (41) arranged in a rotating structure, each box carrier (41) comprising a central opening surrounded by trays (42) for supporting a box (1); and

- an assembly module (50) comprising a punch (51) connected to an ascending and descending arm (52).

2. The machine according to claim 1, CHARACTERIZED in that the punch (51) has a straight base and vertical walls.

3. The machine according to claim 1 or 2, CHARACTERIZED in that the trays (42) are inclined.

4. The machine according to any of the preceding claims, CHARACTERIZED in that it further comprises a transport module (60) with a second conveyor belt (61) that receives an assembled box (1) from the assembly module (50).

5. The machine according to claim 4, CHARACTERIZED in that the transport module (60) comprises an arming sensor (61).

6. The machine according to claim 4 or 5, CHARACTERIZED in that the transport module (60) comprises a separating guide (63) for straps of the assembled box (1).

7. The machine according to any of the preceding claims, CHARACTERIZED in that it further comprises a stacking module (70) that receives boxes from a transport module (60).

8. The machine according to claim 4, CHARACTERIZED in that the stacking module (70) comprises a stacker base (71) connected to an elevator (73), vertical stacking guides (72) and a stacking element (74). ).

9. The machine according to claim 7 or 8, CHARACTERIZED in that it comprises an ejector (72) to remove a stack of boxes (1) from the stacking module (70).

10. The machine according to any of the preceding claims, CHARACTERIZED in that it also comprises an input module (10) with a first conveyor belt to receive boxes (1) upstream of the dosing module (20).

11. The machine according to any of the preceding claims, CHARACTERIZED in that it further comprises an output module (80) with a third conveyor belt (81) to remove a stack of boxes (1) from a stacking module (70).

12. A method for assembling plastic boxes with folding walls by means of the machine according to claims 1 to 11, CHARACTERIZED in that it comprises the steps of: a) stacking boxes in an unfolded configuration inside a dosing module (20); b) releasing a box (1) from a stack of boxes in the dosing module (20) by means of a feeder module (30); c) receiving the box released by the dosing module (20) in a box carrier (41) of a rotating structure of a distribution module (40), said carrier being in a first position (I) and the walls of the box being box (1) supported on trays (42), while the bottom of the box rests on a central opening of said box carrier (41); d) rotate the distribution module (40) until the box carrier (41) that supports the box (1) is in a second position (II); e) lowering a punch (51) connected to an arm (52) of an assembly module (50) and pressing the bottom of the box (1), moving it through the central opening and at the same time lifting the walls of the box, leaving the latter in an armed configuration; and f) repeating the method from step b) onwards.

13. The method according to claim 12, CHARACTERIZED in that it comprises receiving on a second conveyor belt (61) of a transport module (60), the assembled box (1) that comes out from the central opening of the box carrier ( 41).

14. The method according to claim 13, CHARACTERIZED in that it comprises verifying by means of an assembly sensor (61) that the box (1) received in the transport module is properly assembled or is not defective.

15. The method according to claim 14, CHARACTERIZED in that it comprises expelling the box (1) from the machine if the arming sensor (61) detects that the box is not properly armed or is defective.

16. The method according to claim 13 or 14, CHARACTERIZED in that it comprises transporting the assembled box (1) to a stacking module (70) by means of the second conveyor belt (61).

17. The method according to claim 16, CHARACTERIZED in that it comprises assembling a stack of boxes (1) with the assembled boxes received in the stacking module (70).

18. The method according to claim 16 or 17, CHARACTERIZED in that it comprises receiving from the stacking module (70), a stack of boxes (1) assembled in an output module (80) comprising a third conveyor belt (81 ).

19. The method according to any of claims 12 to 18, CHARACTERIZED in that prior to step a) it comprises receiving stacks of boxes (1) in an input module (10) consisting of a first conveyor belt.

20. The method according to claim 19, CHARACTERIZED in that the transfer of the boxes from the input module (10) to the dosing module (20) is carried out manually.

21. The method according to claim 19, CHARACTERIZED in that the transfer of the boxes from the input module (10) to the dosing module (20) is carried out automatically.