TOP LOAD CARTONER
A cartoning method including the steps of: feeding blanks from a single magazine through a single blank feeder in a first direction; forming an array of at least two blanks from the fed blanks and thereafter transporting the array for forming, loading and closing via respective robot kinetics of at least two axis motion. Carton blanks and cartons travel through a path. Robots below the path transport the cartons. Robots above the path facilitate carton forming, loading and closing. Methods and apparatus are disclosed.
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Applicant claims the benefit of the filing date of Mar. 3, 2006 of U.S. provisional patent application Ser. No. 60/779,111 and of the filing date of Oct. 24, 2006 of U.S. provisional patent application Ser. No. 60/854,023, both of the same title as this utility application and both herewith expressly incorporated herein by reference.
FIELD OF THE INVENTIONThis invention relates to cartoners and more particularly to cartoners capable of loading items into cartons or trays through the carton or tray top, rather than from its end or side.
BACKGROUND OF THE INVENTIONTraditional cartoners are generally designed to load cartons from the end or side, where items are pushed into an erected carton and thereafter side or end flaps are glued and closed to finish.
There have been several attempts at top loading cartons or trays with items. In these devices, portions of a flat carton or tray blank, are glued up or a lock mechanism is used to form an open carton or tray which is then loaded from the top. Alternately, the blank is partially formed around an item or group of items placed on the blank, such as in a wraparound process.
Presently, the industry desires to accomplish a variety of packaging formats for a variety of products, and to do so on a single, relative low cost cartoner, with minimal change parts or modules and changeover downtime for different package configurations or size. In this regard, it will be appreciated that packaging machines, such as cartoners, typically operate either continuously or intermittently. That is, the equipment continuously moves items and packages or cartons through a process where they are combined, or the equipment operates intermittently to this end.
Advantages of an intermittent cartoner are typically lower cost, smaller machine footprint and accommodation of many load building and load configuration options. Advantages of a continuous motion cartoner, among others, are high speeds and operational benefits in product loading. The choice of one or the other of these operating processes is typically made at the expense of losing one or more advantages of the other.
Accordingly, one objective of the invention has been to provide a top loading carton apparatus capable of loading items into a variety of package or carton formats and utilizing advantages of both continuous and intermittent cartoning processes.
In another aspect of the cartoning process, it will be appreciated that typical cartoners of the past traditionally erect and convey cartons on a fixed pitch spacing. For example, cartons are conveyed by chain-driven lugs at fixed distances with respect to each other throughout the carton erecting, loading, gluing, closing and discharge operations. Such fixed pitch equipment can be adjusted to different pitch, but this requires downtime, not only in the adjustment of carton conveying lugs but in changeover and adjustment of associated equipment such as loaders, gluers, closers and the like.
Accordingly, it is another objective of the invention to provide a cartoner which is pitchless, that is a cartoner which can handle a variety of blank formats and sizes without regard to pitch (or spacing therebetween) and being easily programmed and adjusted for a wide variety of carton types and spacing, and with minimal downtime and changeover parts.
A further objective of the invention has been to provide an improved top loading cartoner.
SUMMARY OF THE INVENTIONTo these ends, the invention contemplates a cartoner with a unique combination of elements and functions which facilitate the mixing and matching of both continuous and intermittent operations wherever in the process these operations are most beneficial or advantageous. Such operations are carried out sequentially or simultaneously in any desired mix and independently of the nature of an operation in another part of the cartoning process. The invention, in one aspect, contemplates the use of tooling for holding cartons or trays while continuous or intermittent processes as desired are carried out on them. As an example, at least two separately programmable transport robots handle cartons or trays with intermediate tooling. And “Z” or vertical axis motion can be used for particular carton processes.
More particularly, the invention contemplates, in at least one embodiment, a cartoner having a single carton blank feeder (as opposed to multiple feeders) preferably fed by a single blank magazine and for depositing through a single feed point one or a group of cartons on a feeder conveyor. The interaction of the timing of the blank feeder and of the feeder conveyor sets the spacing or pitch between carton blanks on the feed conveyor.
A robot disposed above the cartons, and provided, for example, with vacuum tooling, picks up the cartons and in this embodiment moves them through a glue area (as required), and a die area where the blanks are formed into trays or cartons with open tops.
Another robot, disposed beneath a carton path is provided with tooling to then receive and transport a batch of the formed cartons from the forming area to a load area. During this transport, the carton pitch can, if desired, be closed up by the robot with the cartons moved closer together.
The batch of formed cartons is loaded through open tops by yet a third robot. Thereafter, the cartons are moved to a glue and/or closing station by yet a fourth robot from where the completed trays or cartons are discharged.
In summary in one embodiment, the feeding and forming steps are carried out continuously, in single stream form with arrays of blanks, the loading is performed intermittently and the gluing and closing continuously, with carton pitch varying as desired during the process. Adjunct tooling, elements and the like can be used to operate on or with the cartons or trays as they are held within the end of arm tooling of the robots. For example, pitch of the cartons can be changed.
The invention is facilitated by a unique combination of robots disposed both above and below the carton path, each provided with tooling to handle, form or load cartons or trays through segments of the operation.
It will be appreciated that the operation on the blanks, and the cartons or trays formed from them, are carried out in the various stages of the carton in either continuous or intermittent fashion, depending on which format is most advantageous for the particular operation, and quite independent of the operational format used in other stages of the cartoning process. Thus smaller footprint, product loading and carton specific operations are provided and enhanced, producing a cartoning operation with benefits of both continuous and intermittent motion, and all in a pitchless or pitch varying process. The unique combination of robots oriented for transport below the cartons, combined with robots oriented above the cartons for forming and loading, produce unique and significant results in a top loading cartoner of the invention.
In another embodiment, carton blanks are fed from a single magazine through a single feeder, but are glued as, or just after, they are fed so that an array of glued cartons is provided and there is no need for another glue area or station operating on the array of blanks as in the above embodiment.
It will be appreciated that there is no need in the invention for multiple carton feeders or feeder magazines (even though multiple feeders could be used), thus leaving open a side of the cartoner where such multiple units would otherwise block access.
Use of two or more lower robots beneath the cartoner for carton transport can accommodate whole or half tooling with sufficient clearance or programming control so tooling interference at higher speeds are avoided.
Moreover, it will be appreciated the invention includes the process of forming an array of blanks from a single magazine and feeding blanks into an array through a single infeed point. Also, a process according to the invention includes transporting the blanks between forming and loading stations and between loading and closing stations using a two-axis motion or robotic mechanism.
These and other objectives and advantages of the invention will be readily appreciated from the foregoing, and from the following written description and drawings, in which:
Brief Description of the DrawingsThe accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.
Turning to the drawings, and particularly
The overall process and apparatus of this embodiment are best seen in
As the reciprocating feed arm 17 returns to get the next blank B, the feed conveyor 19 advances in a first direction forward one station to prepare to receive the next blank B.
The process continues until the count of blanks B for the machine set-up is achieved (i.e., usually 2 to 6 blanks), these blanks forming an “array” of blanks. The feed conveyor 19 incorporates additional features such as vacuum hold down, that provide hold-down and positioning capability for the blanks. Four blanks in an array are shown for clarity here.
As used herein, an “array” of blanks describes a group of two or more blanks on which operations can be performed simultaneously. In other embodiments, an “array” could simply describe a blank group.
Once the last blank B (the fourth blank B of
Having received a signal that vacuum has been achieved at each blank B, the Former Robot raises vertically a short distance to disengage from the feed conveyor area 19 and then begins a horizontal move in the direction of arrow 54 perpendicular to the longitudinal flow of the original blank flow stream in the first direction (see the “Position” to “Glue” step of
Having moved away from the feed conveyor 19, the Former Robot passes the array of four carton blanks being carried in a second perpendicular direction over a stationary glue gun region 26 (when needed). Multiple glue guns shoot upward to apply glue at the appropriate positions on the blanks B. It is understood glue may or may not be required at this time.
Continuing the blank motion past the glue gun region 26 in the second direction, the Former Robot carries the array of four carton blanks B into position over the top of the forming or closing die area 28, comprising a plurality of closing dies (not shown in detail).
The Former Robot 22 then plunges the array of carton blanks B preferably downward through individual forming dies to produce the bottom shape of cartons. Depending on the machine set-up, the Former Robot will then either release the open top cartons C at the bottom of the Former Robot stroke, as it hands-off to the below mounted Former-to-Loader Transport Robot 30, or alternately return upward back out the top of the forming dies with the cartons C. If the second approach is used, the Former Robot then moves horizontally an additional distance and then lowers to make the hand-off of cartons to the below mounted Former-to-Loader Transport Robot 30.
Having successfully made the hand-off, the Former Robot 22 returns to the feed conveyor area 19 to repeat its cycle while the Former-to-Loader Transport Robot 30 moves horizontally (perpendicular to the Former Robot flow, see
When the Former-to-Loader Transport Robot 30 arrives in the loading area 32, it stops at the handoff station 33 that engages the cartons C via vacuum to hold the carton positions for the loading process and then subsequent pick-up by the Loader-to-Closing Transport Robot 36.
Once the handoff station 33 has engaged the carton array, the Former-to-Loader Transport Robot 30 lowers slightly downward away from the carton array and then returns back to repeat its cycle. While the Former-to-Loader Transport Robot 30 is returning, the overhead Loader Robot 38 can begin the loading process at the loading area. Various types of suitable robots can be utilized in the loading area, such as an: Overhead Two-axis Robot, SCARA, Six-axis, etc. or any other suitable Robot kinematic can be used. As well, any suitable Robots combined or oriented as described herein may be found useful in the invention.
Having previously picked up the appropriate quantity and configuration of products (not shown) from a product infeed system 40 with its tooling, the Loading Robot 38 is ready to insert the product into the cartons C once they are engaged by the handoff station 33. Depending on the machine set-up, product requirements, and product infeed design, the Loader Robot 38 can pick-up and place multiple cartons' worth of product during each move or alternately fill each of the cartons C individually (even if an array of cartons is being processed through other parts of the machine).
While the loading process is taking place and after the Former-to-Loader Transport Robot 30 disengaged and has started to move away from the handoff station, the Loader-to-Closing Transport Robot 36 can move into position under the carton array in the handoff station 33 and engage the cartons C with its tooling.
When the loading process is complete, the Loader-to-Closing Transport Robot 36 can begin to move horizontally away from the handoff station 33 toward the closing and discharge section 42.
Enroute to the closing area 42 of the machine 14, the Loader-to-Closing Transport Robot 36 carries the carton array past an optional gluing station 44 provided with glue guns (not shown) for glue application to the carton top flaps F. Prior to aligning with the glue guns, the cartons C individually engage fixed guide-work (not shown) that bend the flaps F into proper position to receive the glue.
After the glue is applied, the Loader-to-Closing Transport Robot 36, having never stopped its horizontal motion, continues to carry the carton array past fixed guide-work (not shown) that further moves the flaps into position for final closing.
Having arrived at the closing section 42, the Loader-to-Closing Transport Robot 36 stops its horizontal motion and then moves vertically, pushing the cartons upward through individual stationary dies (not shown). The stationary dies push the carton flaps closed and compress the glue, producing the completed cartons at the top of the Loader-to-Closing Transport Robot up-stroke.
The Loader-to-Closing Transport Robot 36 tooling releases its hold on the cartons and allows a cross-pusher (not shown)of any suitable construction, working perpendicular to the Loader-to-Closing Transport Robot 36 flow, to move the carton array horizontally onto a discharge conveyor (not shown) that carries the cartons out of the machine 14 perpendicular to the flow of the cross-pusher, i.e. in the direction of the machine flow MF or alternately perpendicular thereto.
The Loader-to-Closing Transport Robot 36 retracts downward after the cross-pusher's initial actuation and returns to the handoff station 33 at the appropriate time to repeat its cycle.
With reference to
It will be appreciated that the flow steps illustrated in
It will be further appreciated that Robots 22 and 38 are oriented generally above the plane of carton movement through cartoner 14, while the respective transport robots are oriented below the plan of carton movement through cartoner 14. Each may be respectively provided not only with X-Y translation, but vertical or “Z-axis” translation as well.
Various features of the invention are shown further in
It will be appreciated from
In
Tooling 60 defines carton positions 69, 70 in this embodiment, while tooling 62 defines carton positions 71, 72 thereon.
Also illustrated in
Finally, with respect to
In
a) the location of cartons C-1, C-2 on tooling 64;
b) withdrawal (arrow 74) of tooling 60 by Robot 30, alternately accompanied by a further lowering of tooling 60; and
c) raising of tooling 62 (arrow 76) to raise any cartons (not shown) which are thereon for final closing.
In particular, two transport robots 30, 31 facilitate the former-to-loader transport, similar to that described above, and two transport robots 36, 37 facilitate the loader-to-closer transport, also similar to that described above. However, it will be appreciated that robots 30, 31 each have end-of-arm tooling moveable in a partially common portion of respective “Z”shaped paths so that one transport robot 30 can be delivering cartons to tooling 64, while another transport robot 31 can be receiving cartons from the gluing and forming area.
Each robot 30, 31 has a head or arm 30a, 31a and end-of-arm tooling is mounted thereon. Each robot is capable of Z-axis or vertical movement so in translation, each is respectively raised or lowered as desired to prevent interference with the others as they pass or reset.
Similar construction and motion is provided by robots 36, 37 with respective arms 36a, 37a.
In this manner, it will be appreciated that throughput flow or speeds can be increased with various segments of former-to-loader or loader-to-closer transport taking place simultaneously.
More particularly,
In
Turning now to
It will be appreciated that arrays of four sleeve blanks 90-93 have been fed and formed through the use of the blank feed and Former Robot 22 of
Another blank array comprising four similar sleeve blanks 100-103 have been handed off to tooling 106 at loading station 108. Product cups 110 have been loaded onto respective blanks 100-103 as shown.
In
This operation is further illustrated with further sleeve folding in
Cartons 100-103 are transported perpendicularly to the machine flow MF for discharge as illustrated in
And in
A further alternative embodiment of the invention is illustrated in
Briefly, in this alternative embodiment, individual carton blanks 120-122 (
From there, the blanks 120-122, (
From this position, the entire blank array 130 is picked by a suitable former robot such as robot 22 and is transferred in a second direction perpendicular to the first direction noted above to any suitable former tooling, such as tooling 23, where the blanks in the array 130 are preferably simultaneously formed into open-top trays for subsequent loading through their open tops, closing and discharge as previously described.
This embodiment of the invention thus provides for the grouping, in an array 130, of a predetermined number of blanks (120-122) fed sequentially from a single infeed point, feeder 17 or magazine 18, and provided with glue prior to further downstream operations and prior to formulation of an array of glued blanks.
Such apparatus can be used in a variety of cartoners where it is desired to define a plurality of blanks in an array for subsequent handling of any suitable nature such as described herein or in any other form of cartoning, whether or not as described herein.
It will be appreciated that the carton blanks can be continually fed to the vacuum belts sequentially, while the blanks in the formed array can be simultaneously moved into the former tooling in an intermittent fashion. Moreover, it will be appreciated that any traditional transport apparatus could be used to transfer the blanks, after forming, to and through further downstream cartoning operation.
In addition, further ancillary equipment (not shown) can be used to accomplish further tasks in the process, such as leaflet feeding into the trays, other loading techniques, other closing techniques, such as using an additional downstream robot 134 to accomplish tray closing, discharge and the like.
It will also be appreciated that
It will be further appreciated that this embodiment provides for and contemplates feeding blanks sequentially, from a single magazine and through a single infeed point, gluing blanks sequentially, thereafter forming an array of two or more glued blanks at an array station and transferring the array to a downstream station. Moreover, it will be appreciated that the blank feeding and blank movement through the gluing application is accomplished through movement of the blanks in a single direction or in the same direction, sequentially.
From this disclosure, it will also be appreciated that all the robot devices referred to herein, i.e. robots 22, 30, 36, 38, 80 and 82, for example, may comprise any suitable robot apparatus individually well known. More particularly, and whether or not technically qualifying as a robot, per se, this apparatus according to the invention preferably comprises at least a two axis programmable apparatus sufficient to produce the movements described herein (such as pick and place) and combined according to the invention.
It will be immediately appreciated from the foregoing that the invention provides several unique advantages. One such major advantage is the pitchless operation of the invention. In the embodiment of
In this regard, and for example, it is possible with the invention to adapt a wide variety of loading mechanisms and functions for use with the invention without having to purchase or change out the entire cartoner.
Another aspect of the invention which produces these results is the unique combination of plural robots or two axis programmable apparatus in combined overhead and underneath disposition respecting the cartons. Use of overhead former and loading apparatus combined with underneath transport apparatus is thus highly advantageous in producing a multi-functional top load cartoner.
Moreover, the ability to use only a single blank feeder to provide blank arrays in multiple pitch for a variety of varied pitch carton formats comprises a significant advantage to cartoners where footprint, cost and adaptability are significant.
A significant advantage of the invention is the capacity to provide a cartoning machine and process with both continuous and intermittent operations in the same cartoning process and independently so the advantages of these operational formats can be used to obtain the beneficial aspects of each, as desired, without restriction by the operation of a separate process segment operating in a different format. Each operating segment including carton control, forming, transport, loading, closing and discharge can each be carried out continuously or intermittently, independently of and decoupled from other operational segments, providing beneficial cartoning and overall cartoning enhancement.
It will also be appreciated that it is possible to carry out procedures on the cartons while they are in motion between the specific stations described herein. In this regard, the arm end tooling holds and/or manipulates the cartons during their transport.
It will also be appreciated that in the embodiments disclosed, the blanks and formed trays or cartons are maintained under positive control throughout the process from blank feeding to loaded and closed tray discharge.
Finally, it will be appreciated that the carton blanks and cartons move through a path or a plane as they are fed, glued, formed, loaded, closed and discharged. The invention contemplates carton handling by transport robots oriented beneath the path or plane, and carton loading or other manipulation by robots or other multiple axis apparatus oriented above the path or plane. Such path or plane has a “thickness” or depth defined by the carton travel.
These and other advantages, embodiments and modifications will be readily apparent from the foregoing to those of ordinary skill in the art without departing from the scope of the invention and applicant intends to be bound only by the claims appended hereto.
Claims
1. A cartoning method including the steps of:
- feeding blanks from a single magazine through a single blank feeder in a first direction; and
- forming an array of at least two blanks of predetermined number from said blanks.
2. A method as in claim 1 including the step of:
- applying glue sequentially to cartons being fed from said feeder prior to the formation of said array.
3. A method as in claim 1 including the step of:
- applying glue to said fed blanks after forming them into said array.
4. A method as in claim 1 including the further step of:
- moving said array in a second direction perpendicular to the first direction in which carton blanks are fed from said feeder.
5. A method as in claim 1 including transporting said array to a carton forming station and there at least partially forming cartons from said blanks in said array.
6. A method as in claim 1 including the further steps of:
- transporting cartons from said carton forming station to a loading station and there loading items into said cartons;
- transporting loaded cartons to a closing station and closing loading cartons; and
- discharging cartons.
7. A method as in claim 6 including transporting cartons from said carton forming station to said loading station by a robot having at least a two-axis motion.
8. A method as in claim 6 including transporting cartons from said loading station to said closing station by a robot having at least a two-axis motion.
9. A method of cartoning, including the forming, transporting and loading of cartons in selected carton arrays of two or more cartons, and including the steps of:
- feeding carton blanks onto a feed conveyor at a single infeed location from a single carton blank feeder; and
- forming an array of carton blanks on a feed conveyor by said feeding.
10. A method of handling carton blanks and including the steps of:
- feeding carton blanks sequentially from a single infeed point;
- applying glue sequentially to said fed blanks;
- forming, at an array station, an array of blanks, having glue applied thereto; and
- transferring said array away from said array station.
11. A method as in claim 9 wherein the steps of feeding and applying glue to said blanks includes moving said blanks in the same direction during said feeding and said glue applying.
12. A method of cartoning wherein a plurality of operations are carried out on cartons and including the steps of conducting some of said operations in a continuous motion and some in an intermittent motion and wherein said motions are decoupled one from the other.
13. A method of cartoning wherein products are loaded into cartons and including the steps of:
- forming cartons;
- transporting formed cartons to a loading station;
- loading cartons; and
- transporting cartons from said loading station;
- wherein at least one of said steps is carried out in continuous motion and another of said steps is carried out in intermittent motion and wherein said respective motions are decoupled one from the other.
14. A method as in claim 13 wherein said forming, transporting and loading steps are all carried out by robots having at least two axes of motion and including the further step of selectively raising and lowering cartons with said robots during said cartoning.
15. A method as in claim 13 including:
- engaging such cartons in end-of-arm tooling on a robot; and
- performing a carton manipulating operation on cartons while said cartons are engaged by said tooling.
16. Apparatus for handling carton blanks, said apparatus including:
- a blank feeder defining a single infeed;
- a blank conveyor oriented to receive fed blanks from said single infeed and for transferring said blanks to a glue station;
- glue apparatus oriented to apply glue to blanks transported there-past; and
- an array orienting station downstream of said glue apparatus.
17. Apparatus as in claim 16 and further including a blank receiving apparatus receiving fed blanks sequentially from said infeed and transferring fed blanks to said conveyor.
18. Apparatus as in claim 16 wherein said blanks are fed sequentially onto said blank conveyor in a first direction, said conveyor oriented for moving said blanks in a single direction from said infeed past said glue apparatus.
19. Apparatus as in claim 18 including transfer apparatus for moving an array of said blanks, downstream of said glue apparatus, in a second direction, perpendicular to said first direction, toward a carton forming station.
20. A cartoner comprising:
- a former robot;
- a former-to-loader transport robot;
- a loader robot; and
- a loader-to-closer transport robot
- said robots operationally interconnected to form, transport, load and further transport loaded cartons.
21. A cartoner as in claim 20 wherein said former and loader robots are oriented above a path of movement of said cartons and said respective transport robots are oriented below said path.
22. A cartoner as in claim 21 further including end-of-arm tooling respectively carried by respective ones of said robots.
23. A cartoner as in claim 22 further including at least two sets of end-of-arm tooling, each set facilitating loading of cartons oriented at a different pitch from cartons whose loading is facilitated by the other set.
24. Cartoning apparatus comprising:
- a single magazine;
- a feeder for feeding blanks received from said single magazine in a first direction;
- a conveyor for receiving at least two blanks defining an array of blanks; and
- apparatus having motion in at least two axes for moving said array from said conveyor toward a carton forming apparatus.
25. Apparatus as in claim 24 further including a robot for transporting an array of cartons from a carton former station to a carton loading station.
26. Apparatus as in claim 25 wherein said robot is disposed beneath a path in which said array of cartons passes and said apparatus for moving said array from said conveyor toward a carton forming apparatus is disposed above said path.
27. Apparatus as in claim 25 further including two robots for transporting an array of cartons from a carton former station to a carton loading station.
28. Apparatus as in claim 24 further including a robot for transporting an array of cartons from a carton loading station to a carton closing station.
29. Apparatus as in claim 28 further including a robot for loading items into said array of cartons and wherein said robot for transporting is disposed beneath a path in which said array of cartons moves and said robot for loading items is disposed above said path.
30. Apparatus as in claim 27 further including two robots for transporting an array of cartons from a carton loading station to a carton closing station.
Type: Application
Filed: Mar 2, 2007
Publication Date: Sep 6, 2007
Applicant: R.A. Jones & Co. Inc. (Covington, KY)
Inventors: Jeffrey Wintring (Florence, KY), Robert Burkhardt (Fort Mitchell, KY), Christopher George (Cincinnati, OH), Anthony Salvato (Cincinnati, OH)
Application Number: 11/681,434
International Classification: B65B 43/26 (20060101);