Apparatus and method for accurate carton formation

Abstract

A carton forming machine includes a carton blank push up device that receives a substantially horizontal folded carton blank and reorients the folded carton blank from the substantially horizontal orientation to an upright orientation below and in a first direction alignment with a carton opening mechanism. A carton blank positioning apparatus shifts the upright folded carton blank in a second direction, transverse to the first direction, below the carton opening mechanism to define a second direction position of the upright carton blank below the carton opening mechanism before the carton opening mechanism engages the upright carton blank for opening of the upright carton blank.

Claims

1. A carton forming machine, comprising: a carton blank storage rack holding a carton blank stack formed by a plurality of substantially horizontal folded carton blanks; a carton blank transport device arranged to pick a folded carton blank from the carton blank stack and transport the folded carton blank in a conveyance direction along a conveyance path toward a carton opening mechanism; a carton blank push up device that receives the folded carton blank from the carton blank transport device and reorients the folded carton blank from the substantially horizontal orientation to an upright orientation below the carton opening mechanism to provide an upright folded carton blank; and a carton blank positioning apparatus that receives and supports the upright folded carton blank and shifts the upright folded carton blank in a set direction transverse to the conveyance direction in order to establish an accurate lateral position of the upright folded carton blank below the carton opening mechanism before the carton opening mechanism engages the upright carton blank for opening of the upright carton blank; wherein the carton blank positioning apparatus includes an elongated bar with an upward facing receiving slot in which bottom edges of flaps on the upright folded carton blank are positioned, wherein the elongated bar, including the upward facing receiving slot, is movable in the set direction in order to shift the upright folded carton blank in the set direction to establish the accurate lateral position; wherein the carton blank push up device receives the folded carton blank from the carton blank transport device at a location in which the folded carton blank is spaced, along the conveyance direction, from the upward facing receiving slot of the carton blank positioning apparatus.

2. The carton forming machine of claim 1 wherein the carton blank transport device is arranged above the carton blank storage rack and picks the folded carton blank from a top of the carton blank stack, the carton blank transport device including at least one suction cup to engage the folded carton blank.

3. The carton forming machine of claim 1 wherein the carton blank positioning apparatus includes a stop surface in line with one end of the elongated bar, the elongated bar moves in the set direction such that one side of the upright folded carton blank contacts the stop surface to define the accurate lateral position of the upright folded carton blank.

4. The carton forming machine of claim 3 wherein after the one side of the upright folded carton blank contacts the stop surface continued movement of the elongated bar in the set direction causes the elongated bar to slide relative to the upright folded carton blank sitting in the upward facing receiving slot.

5. The carton forming machine of claim 3 wherein a position of the stop surface along the set direction is adjustable to permit adjustment to accommodate different carton blank sizes.

6. The carton forming machine of claim 1 wherein the elongated bar is in a first position when the upright folded carton blank is initially loaded into the upward facing receiving slot, and one side of the upright folded carton blank protrudes beyond one end of the elongated bar.

7. A carton forming machine, comprising: a carton blank push up device that receives a substantially horizontal folded carton blank and reorients the substantially horizontal folded carton blank to an upright orientation to provide an upright folded carton blank below and in a first direction alignment with a carton opening mechanism; and a carton blank positioning apparatus that shifts the upright folded carton blank in a second direction, transverse to the first direction, below the carton opening mechanism to define a second direction position of the upright folded carton blank below the carton opening mechanism before the carton opening mechanism engages the upright folded carton blank for opening of the upright folded carton blank; wherein the carton blank positioning apparatus includes an elongated member with an upward facing slot supporting bottom edges of flaps on the upright folded carton blank and the elongated member, including the upward facing slot, is movable in the second direction in order to define the second direction position; wherein the carton blank positioning apparatus includes a stop surface toward one end of the elongated member, wherein the elongated member, including the upward facing slot, is movable in the second direction such that one side of the upright folded carton blank contacts the stop surface to define the second direction position of the upright folded carton blank.

8. The carton forming machine of claim 7 wherein the carton blank positioning device includes a top flap pusher movable between an upright position and a lowered push position, in the upright position the top flap pusher is above a travel path of the substantially horizontal folded carton blank as the substantially horizontal folded carton blank moves from the substantially horizontal orientation to the upright orientation, in the lowered push position the top flap pusher engages a trailing side of top flaps of the substantially horizontal folded carton blank.

9. The carton forming machine of claim 8 wherein the top flap pusher is mounted for pivotal movement between the upright position and the lowered push position.

10. The carton forming machine of claim 8 wherein the top flap pusher pushes a leading side of some of the top flaps against a panel member of the carton forming machine.

11. The carton forming machine of claim 7 wherein the carton blank push up device includes a first gripper and a second gripper, the first gripper has a fixed position and the second gripper is movable in the second direction to enable adjustment of a spacing between the first gripper and the second gripper to accommodate different carton blank sizes.

12. The carton forming machine of claim 11 wherein an actuator is operatively connected for movement of the second gripper, and the actuator is controllable by a switch that is configured to be manually activated when the carton forming machine is not operating to form cartons.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of the carton forming machine with folded carton blanks storage rack and folded carton blank opening device;

(2) FIG. 2 is a side view of the carton forming machine from folded carton blanks storage rack to folded carton blank opening device;

(3) FIG. 3 is a top view of the carton forming machine from folded carton blanks storage rack to Folded carton blank opening device;

(4) FIG. 4 is a perspective view of the folded carton blanks transport device and folded carton blank vertical transport device;

(5) FIG. 5 is a perspective view of the carton blanks transport conveyor device;

(6) FIG. 6 is a perspective view of the folded carton blank pick up device;

(7) FIG. 7 is a perspective view of the folded carton blank stand up device;

(8) FIG. 8A-8D is different view of the folded carton blank stand up device;

(9) FIG. 9 is a perspective view of the top flap push device;

(10) FIG. 10A-10D is different view of the top flap push device;

(11) FIG. 11 is a perspective view of the accurate carton apparatus and bottom flap position device;

(12) FIGS. 12-18B depict an illustration of how the carton blanks feeding system transports carton blanks to the carton blanks erecting device;

(13) FIG. 19 is a schematic side elevation of the case forming apparatus; and

(14) FIG. 20 is a schematic top plan view of FIG. 19 with carton opening device not shown.

DETAILED DESCRIPTION

(15) Referring to FIGS. 19 and 20, the basic operation of a carton feed assembly of a carton forming machine is shown schematically. A carton blank storage rack 21 holds a carton blank stack formed by a plurality of substantially horizontal folded carton blanks 6. The storage rack includes a conveyor belt mechanism 217 that can also be raised to feed the carton blank stack upward, and lowered to load more carton blanks, per arrow 217a. A carton blank transport device 22 is movable per arrows 22a and is arranged to pick a folded carton blank from the top of the stack (position A1) and transport the folded carton blank in a conveyance direction CD along a conveyance path toward a carton opening mechanism 1 (into position A2). A carton blank push up or stand up device 7 receives the folded carton blank from the carton blank transport device (at position A2) and reorients the folded carton blank from the substantially horizontal orientation to an upright orientation below the carton opening mechanism 1 (position A3). A carton blank positioning apparatus 82 (also referred to as an accurate carton apparatus) receives and supports the upright folded carton blank and is movable per arrows 82a to shift the upright folded carton blank in a set direction SD transverse (here substantially perpendicular) to the conveyance direction CD in order to establish an accurate lateral position of the upright folded carton blank below the carton opening mechanism 1 before the carton opening mechanism engages the upright carton blank for opening of the upright carton blank. Thus, a correct position of the carton blank in both direction CD and direction SD, relative to the overhead carton opening mechanism 1, is achieved. The carton opening mechanism 1 may be of a type utilizing jaw plates with pins that engage the carton as describe in any of U.S. Pat. No. 4,553,954 or later variations such as those shown in U.S. Pat. Nos. 7,131,941, 7,192,393 or 7,422,552. The carton opening mechanism shifts the carton blank slightly in further direction SD as the carton blank is opened, and can then be moved downward into contact with the flap closing arms to close the bottom of the carton. The opened carton blank can then be conveyed further in set direction SD to a bottom tape sealing device (not shown) that tapes the bottom of the opened carton blank.

(16) The carton blank transport device 22 is arranged above the carton blank storage rack and picks the folded carton blank from a top of the stack. The transport device 22 may include a pair of suction cups to pick up the carton blank and is movable along a support rail per arrows 22a, as will be described in greater detail below. The transport device 22 also moves up and down per arrows 22b (which may be achieved by a pivoting motion of the device about a horizontal axis 22c as will be described in further detail below).

(17) The carton blank positioning apparatus includes an elongated bar/rail/member with an upward facing receiving slot or groove 825 in which bottom edges of flaps on the carton blank are positioned when the carton blank is moved into the upright orientation. The elongated bar/rail/member 82 is movable in the set direction SD. The carton blank positioning apparatus 82 includes a stop surface 9 toward one end of the elongated bar/rail/member. The elongated bar/rail/member moves in the set direction SD such that one side of the upright carton blank contacts the stop surface 9 to define the accurate lateral position of the upright folded carton blank. After the one side of the carton blank contacts the stop surface 9, continued movement of the elongated bar/rail/member in the set direction causes the elongated bar to slide relative to the upright carton blank sitting in the receiving slot/groove. A position of the stop surface 9 along the set direction SD may be adjustable to permit adjustment to accommodate different carton blank sizes. The elongated bar/rail/member is in a first position when the upright carton blank is initially loaded into the receiving slot, and one side of the upright carton blank protrudes beyond one end of the elongated bar when initially loaded, as per FIG. 20. The elongated bar/rail/member 82 can also be moved up and down per arrows 82b in order to engage the upright carton blank onto the carton opening device 1.

(18) The carton blank positioning device includes a top flap pusher 81 movable between an upright position (shown in FIG. 19) and a lowered push position (achieved per arrow 81a). In the upright position, the top flap pusher 81 is above a travel path of a carton blank as the carton blank moves from the substantially horizontal orientation to the upright orientation, and in the lowered push position, the top flap pusher engages a trailing side of the carton blank top flaps. As shown, the top flap pusher may be mounted for pivotal movement between the upright position and the lowered push position. The top flap pusher 81 pushes a leading side of some of the top flaps against a panel member of the carton opening mechanism 1.

(19) Thus, a method of handling carton blanks in a carton forming machine, the method comprising: (a) storing a plurality of substantially horizontally oriented folded carton blanks in a stack at a carton blank station; (b) automatically picking a folded carton blank from the top of the stack and conveying it in a substantially horizontal orientation along a conveyance path in a first direction toward a carton opening mechanism; (c) automatically shifting the folded carton blank of step (b) upward into an upright orientation with a first set position that is below and in a first direction alignment with the carton opening mechanism; and (d) automatically shifting the folded carton blank of step (c) in a second direction, transverse to the first direction, and into a second set position that is below and in a second direction alignment with the carton opening mechanism. For continuous operation, repeating steps (b), (c) and (d) for multiple folded carton blanks in the stack takes place. In step (c), the shifting operation loads the folded carton blank into a receiving slot in a bar/rail/member, and in a step (e) after step (d), the bar/rail/member upward to push the folded carton blank into engagement with a carton opening mechanism that operates to open the folded carton blank.

(20) Referring now collectively to FIGS. 1-20, various detailed structures of the machine are shown. At the front part of the carton forming machine 1 is the folded carton blanks feeding system 2 which include a folded carton blanks storage rack 21, a folded carton blanks transport device 22 and a blocking plate 23. The said folded carton blanks storage rack 21 has four long flat metal bars 211, the four long flat metal bars 211 form the legs of the folded carton blanks storage rack 21. Another four flat bars 212 are mounted on the top of the four long flat metal bars 211 so as to form the frame of the folded carton blanks storage rack 21. In the folded carton blanks storage rack 21, the folded carton blanks transport device 22 is mounted. On the flat bars 212, a motor 213 which belongs to folded carton blanks transport device 22 is mounted. The motor 213 is connected with five pulleys 214 by one driven belt 215. Three of the said pulleys 214 are connected to three vertical threaded shafts 216. The said three vertical threaded shafts 216 are mounted on the opposite sides of the folded carton blanks storage rack 21 and pass through two metal plates 219 and a vertical bar 210 so as to link with the conveyor belt 217. The conveyor belt 217 is driven to move inward and outward by another motor 218. At the front end of the conveyor belt 217, a blocking plate 23 is installed to avoid the falling of the folded carton blanks into the machine. At one side of the folded carton blanks storage rack 21, a big “” shape metal bar 3 is mounted to connect the folded carton blanks storage rack 21 with the carton forming machine 1. Above the big “” shape metal bar 3, another long small metal bar 4 is mounted. This long small metal bar 4 is used for the folded carton blank pick up device 5 to mount on it.

(21) When working, a pile of horizontal folded carton blanks 6 is placed at the entrance of the carton blank storage rack 21, then the motor 218 will drive the conveyor belt 217 to move inward to take the pile of horizontal folded carton blanks 6 from the entrance of the folded carton blanks storage rack 21 into the storage rack 21. The blocking plate 23 will prevent the pile of horizontal folded carton blanks 6 from falling into the machine. Then, the motor 213 of the folded carton blanks transport device 22 will drive the five pulleys 214 and the one driven belt 215 to move and as the pulleys 214 are connected with the three vertical threaded shafts 216, then the three vertical threaded shafts 216 will drive the conveyor belts 217 to move upward for folded carton blank pick up or move downward for re-load of folded carton blanks. At the same time, the folded carton blank pick up device 5 is starting to pick up the top horizontal folded carton blanks 61. The folded carton blank pick up device has two suctions cups 51 which are mounted on a “” shaped short plate 52, this “” shaped short plate 52 is mounted on a flat plate 53 and the flat plate 53 is mounted on two vertical small bars 56. The two vertical small bars 56 connected with a moving bar 54 and a pneumatic cylinder 55 is linked with the flat plate 53 and is used to push the suction cups 51 to swing down to pick up the top horizontal folded carton blanks 61 to the folded carton blank stand up device 7. The folded carton blank stand up device 7 is composed of a long flat plate 71, two grippers 72, a long rod 73 and a pneumatic cylinder 74.

(22) The accurate carton apparatus 8 is mounted behind the folded carton blank stand up device 7. The said accurate carton apparatus 8 has a bottom flap position device 82 and upward driving pneumatic cylinder with vertical slide 829. The top flap push device 81 includes a long rod 811, a “” shaped plate 812 and a pneumatic cylinder 813. The bottom flap position device 82 has a “” shape bar 821, a small long bar 822, a moving rail 823, and a pneumatic cylinder 824.

(23) The folded carton blanks storage rack 21 is mounted at the front of the carton forming machine 1. The folded carton blanks transport device 22 is mounted in the folded carton blanks storage rack 21 and at the end of the folded carton blanks transport device 22 is the folded carton blank pick up device 5. At the side of the folded carton blank pick up device 5 is the folded carton blank stand up device 7. The accurate carton apparatus 8 is located behind the folded carton blank stand up device 7.

(24) The carton blanks feeding system 2 includes a folded carton blanks storage rack 21, a folded carton blanks transport device 22 and a blocking plate 23. The folded carton blanks storage rack 21 has four long flat metal bars 211 and they form the legs of the folded carton blanks storage rack 21. On the top of the four long flat metal bars 211, four flat bars 212 are mounted to form the frame of the folded carton blanks storage rack 21. In FIG. 4, the folded carton blanks transport device 22 is composed of a motor 213, five pulleys 214 which are linked with one driven belt 215, a conveyor belt 217 and a motor 218. Three of the said pulleys 214 are mounted on three vertical threaded shafts 216. When the motor 213 drives the driven belt 215 to move, then the pulleys 214 connected with the driven belt 215 are also moved; as the pulleys 214 are connected with the three vertical threaded shafts 216, the action will drive the conveyor belt 217 moving upward for top horizontal folded carton blank 6 pick up or moving downward for re-load of folded carton blanks. The motor 218 can move the conveyor belt 217 inward or outward so as to help load or eject the folded carton blanks.

(25) At the one side of the conveyor belt 217, two metal plates 219 are mounted and each metal plate 219 has a hole 2191 on the center which allows the vertical long moving rods 216 to pass through. At the opposite side, a vertical bar 210 is mounted with the conveyor belt 217. The said vertical bar 210 is used for one of the vertical long moving rod 216 to link with. In FIG. 5, the motor 218 is located at the side of the conveyor belt 217, which is used to drive the conveyor belt 217 to move inward or outward.

(26) The folded carton blank pick up device 5 hastwo suction cups 51 which are mounted on a “” shape short plate 52, this “” shape short plate 52 is mounted on a flat plate 53 and the said flat plate 53 is mounted on two vertical small bars 56. Then the two vertical small bars 56 are mounted a rectangular shape plate 57 and this rectangular shape plate 57 is mounted on a moving bar 54 and a pneumatic cylinder 55 is used to push the suction cups 51 to swing down to pick up the top horizontal folded carton blanks 61. Another pneumatic cylinder 58 is mounted at the bottom of the rectangular shape plate 57, it is used to move forward or backward of suction cups 51 that are mounted on the rectangular shape plate 57. The forward movement lets the suction cups 51 to reach the carton storage rack 21 to pick the top horizontal folded carton blank 61 and go back to the original position to place the horizontal folded carton blank 61 on the folded carton blank stand up device 7.

(27) The folded carton blank stand up device 7 composed of a long flat plate 71, two grippers 72, a long rod 73 and a pneumatic cylinder 74. The said long flat plate 71 is mounted on two metal plates 75, 76 respectively. On the top of the metal plate 75, a gripper 72 is mounted and cannot move. A movable rod 77 is also mounted on the middle of the two metal plates 75, 76. This movable rod 77 allows another gripper 72 to mount on it and the said gripper 72 is movable along the movable rod 77 with a switch 721. The purpose of the movable gripper 72 is to allow the adjustment of the distance between the two grippers 72 so as to hold abnormally large or small size folded carton blanks. Adjustment requires only switching the switch 721 and move the gripper 72 and locking the switch 721 again, which is very easy. Below the movable rod 77, a bar 78 is mounted between the two metal plates 75, 76. At the middle of the bar 78, a “∩” shape small metal 781 is mounted which is used to link with the pneumatic cylinder 74. At the back of the long flat plate 71, two small rods 711 are mounted and connected to the long rod 73. The two metal plates 75, 76 are connected to two long rectangular bars 79. The two long rectangular bars 79 allow the two metal plates 75, 76 to be movable. At the back of the two long rectangular bars 79, another long bar 791 is mounted to the bars and on the blocking plate 23. In FIG. 7, the two long rectangular bars 79 are mounted on two small metal bars 792.

(28) FIGS. 8a-8d is different views of the folded carton blank stand up device 7. FIG. 8a, FIG. 8c and FIG. 8d show the top, side and front views of the folded carton blank stand up device 7. FIG. 8b shows the structure view of the folded carton blank stand up device 7.

(29) At the back of the long flat plate 71, two small rods 711 are mounted. The two small rods 711 are connected with the long rod 73. One of the gripper 72 is mounted on the metal plate 75 and cannot move. The two metal plates 75, 76 are connected with two long rectangular bar 79. The whole folded carton blank stand up device 7 is mounted on the blocking plate 23.

(30) The top flap push device 81 of the accurate carton apparatus 8 includes a long rod 811, a “” shape plate 812 and a pneumatic cylinder 813. The long rod 811 has a pair of flat plates 814 which are used to mount on the “” shape plate 812. At the center of the long rod 811, two plates 815 are mounted. The two plates 815 connected with a “” shape metal 816. At the center of the “” shape plate 812, a hole 817 is used to let the vertical “r” shape bar 818 to pass through. The vertical “” shape bar 818 is mounted to the pneumatic cylinder 813 and the pneumatic cylinder 813 is connected to the “” shape metal 816 to allow the pneumatic cylinder 813 to push the long rod 811 forward and backward in order to press the folded carton blank 61 firmly under the folded carton blank opening device (known technology).

(31) The bottom flap positioning device 82 of the accurate carton apparatus 8 has a “” shape bar 821, a small long bar 822, a moving rail 823, and a pneumatic cylinder 824. The “” shape bar 821 and the small long bar 822 are mounted together and form a groove 825. The groove 825 allows the bottom flap of the folded carton blank 61 to fall in it. The “” shape bar 821 and the small long bar 822 are mounted on a trapezoid shape flat bar 826. The trapezoid shape flat bar 826 is connected with four rods 829. These four rods 829 are mounted on a thick metal bar 827. The thick metal bar 827 is mounted on a flat plate 828. On the other side of the flat plate 828, a moving rail 823 is mounted. At the front end of the flat plate 828, the pneumatic cylinder 824 is mounted. The pneumatic cylinder 824 will push the flat plate 828, which is linked with the “” shape bar 821 and the small long bar 822, causing movement forward or backward in order to position the bottom flap of the folded carton blank 61 by hitting the side of the folded carton blank 61 to the position bar 9 located at the side under the folded carton blank opening device for flaps opening.

(32) FIG. 12-18b show the operational views depicting how the carton forming machine 1 moves and stretches open a horizontal folded carton blanks 61. In FIG. 12, a pile/stack of horizontal folded carton blanks 6 is placed in the folded carton blanks storage rack (not shown). The suction cups 51 of the folded carton blank pick up device 5 are in an up position, which is in preparation to pick up a horizontal folded carton blank 61. Per FIG. 12, the rectangular shape plate 57, is controlled by the pneumatic cylinder 58 to move forward to the pile of horizontal folded carton blanks 6 and the suction cups 51 are controlled by the pneumatic cylinder 55 swing down to pick up the top horizontal folded carton blank 61. At the same time, the folded carton blank stand up device 7 and the accurate carton apparatus 8 are in a ready state. FIGS. 14a and 14b are the different views showing how the folded carton blank 61 is transported to the folded carton blank stand up device 7. In detail, after the suction cups 51 pick up the folded carton blank 61, the pneumatic cylinder 58 will move backward and transport the folded carton blank 61 to the folded carton blank stand up device 7. In FIGS. 15a and 15b, after the suction cups 51 place the folded carton blank 61 on the folded carton blank stand up device 7, the suction cups 51 will release the folded carton blank 61 and the pneumatic cylinder 55 will drive the flat plate 53 back to an up position. Referring to FIG. 16, the folded carton blank 61 is pushed up gradually by the folded carton blank stand up device 7, and the bottom flap of the folded carton blank 61 is inserted inside the groove 825 under folded carton blank opening device. FIGS. 17a-17c show the folded carton blank 61 standing vertically under the folded carton blank opening device and the bottom flap of the folded carton blank 61 within the groove 825 formed between the said “” shape bar 821 and the small long bar 822. In order to prevent the folded carton blank 61 from falling back down, the long rod 73 and the long flat plate 71 of the folded carton blank stand up device 7 remain in the vertical position so as to press the folded carton blank 61 to stand vertically. At the same time, in order to aid in preventing the folded carton blank 61 falling back, the long rod 811 of the top flap push device 81, controlled by pneumatic cylinder 813 will press the folded carton blank 61 against the folded carton blank opening device. As shown in FIGS. 18a and 18b, the folded carton blank 61 stands vertically with the bottom flap entered into the groove 825 formed by the said “” shape bar 821 and the small long bar 822. The pneumatic cylinder 824 of the accurate carton apparatus 82 will then move backward, causing the “” shape bar 821 and the small long bar 822 to also move backward and causing the side of the folded carton blank 61 to move into contact with the positioning bar 9 and finally position the folded carton blank 61 accurately under the folded carton blank opening device.

(33) It is to be clearly understood that the above description is intended by way of illustration and example only, is not intended to be taken by way of limitation, and that other changes and modifications are possible.