PACKAGING DEVICE AND PROCESS FOR ARTICLES TO BE PACKAGED

Abstract

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

Claims

1-17. (canceled)

18. A continuously operating packaging device for articles to be packaged fed on a first conveyor line, said packaging device comprising: a second conveyor line placed in proximity of said first conveyor line, said second conveyor line being configured to convey a flow of box-shaped packagings in an open configuration, said box-shaped packagings configured to be filled with said articles in layers of articles having predetermined dimensions; transfer devices for picking the articles from said first conveyor line and inserting the articles in a respective target box-shaped packaging, each transfer device comprising a handling member and a gripping device controlled by said handling member, both being movable along three orthogonal axes; and a control unit for controlling the transfer devices, comprising a collection of laws of motion and/or relevant trajectories defining movement of said transfer devices, wherein a set of laws of motion and/or relevant trajectories is selected from said collection according to number and predetermined size of the layers of articles configured to be grouped in said box-shaped packagings.

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

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

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

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

23. The packaging device according to claim 18, comprising one or more image detecting devices, each corresponding to at least one respective transfer device (200), and positioned near the flow of box-shaped packagings, said one or more image detecting devices being configured to detect conformity of the layers downstream of each transfer device with respect to said flow, said control unit being configured to receive (i) a signal, from the one or more image detecting devices, for correct placing of the layers, or (ii) an alarm signal for incorrect placing of the layers.

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

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

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

27. A continuous packaging process for articles to be packaged fed on a first conveyor line, in a flow of respective box-shaped packagings in an open configuration conveyed on a second conveyor line, said process comprising: a picking step of picking the articles from said first conveyor line, performed by transfer devices; a transfer step of transferring the articles from said first conveyor line to said second conveyor line; and a forming step of forming layers of articles in said box-shaped packagings by inserting picked articles into a respective box-shaped packaging, wherein, in the transfer step, said transfer devices move according to laws of motion and/or relevant trajectories selected from a collection of laws of motion and relevant trajectories, wherein a set of movement laws and/or relevant trajectories for said transfer devices is selected from said collection according to a predetermined size and a number of layers placed in said box-shaped packagings.

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

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

30. The packaging process according to claim 27, further comprising: a detecting step of detecting images of the layers formed in said forming step and, in case of incorrect formation of the layers of the articles previously inserted in a box-shaped packaging, an emission step of emitting a non-conformity signal for the already inserted layers.

31. The packaging process according to claim 30, further comprising, in case of emission of the non-conformity signal, a placing step of placing the articles, following the picking step, in buffers provided at said first conveyor line.

32. The packaging process according to claim 31, further comprising: an additional picking step of picking the articles from said buffers, an additional transfer step of transferring the articles from said buffers to said second conveyor line, and a complementary step of forming layers of said articles in said box-shaped packagings by inserting picked articles in a respective target box-shaped packaging.

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

Description

[0145] The characteristics and advantages of the invention will become clearer from the detailed description of an embodiment illustrated, by way of non-limiting example, with reference to the appended drawings wherein:

[0146] • FIG. 1 shows a first perspective view of an embodiment of a packaging apparatus comprising a device for packaging articles according to the present invention;

[0147] • FIG. 2 shows a second perspective view of the packaging apparatus of FIG. 1, from a different point of view to that of the previous figure to show the opposite side;

[0148] • FIG. 3 shows a plan view from above of the packaging apparatus in FIG. 1;

[0149] • FIG. 4 shows a first partial perspective view of the packaging apparatus in the previous figures;

[0150] • FIG. 5 shows a second partial perspective view of the packaging apparatus of the previous figures;

[0151] • FIG. 6 shows a third partial perspective view of the packaging apparatus of the preceding figures, which allows to visualize the device for packaging articles made according to the present invention;

[0152] • FIG. 7 shows an enlarged view of a detail of the packaging device in FIG. 6;

[0153] • FIG. 8 shows a side view of the device of FIG. 6;

[0154] • FIG. 9 shows an enlarged perspective view of a transfer device of the packaging device from FIG. 6;

[0155] • FIG. 10 shows a plan view from below of a first detail of the transfer device in FIG. 9;

[0156] • FIG. 11 shows a side perspective view of a second detail of the transfer device in FIG. 9;

[0157] • FIG. 12 shows an elevation view of an article to be packaged;

[0158] • FIG. 13 shows a side view illustrating the arrangement of the articles to be packaged in a box-shaped packaging; and

[0159] • FIG. 14 shows a view from above illustrating the arrangement of the articles to be packaged in the box-shaped packaging of FIG. 13.

[0160] In the accompanying figures, 100 indicates as a whole an apparatus for packaging articles to be packaged 1, comprising a packaging device 400 made in accordance with the present invention, which in turn comprises a feeder device 300 operating on the head thereof.

[0161] The embodiment described below refers to articles to be packaged in a packaging, in particular a box-shaped packaging 30 in which articles that are different from each other, or the same but in different configurations, are arranged in a sorted manner on superimposed layers.

[0162] In this example, with reference to FIGS. 12 to 14, a particular article to be packaged for non-limiting purposes, namely a capsule 1, is contemplated, such as a capsule for the production of drinks by infusion.

[0163] The capsule 1 is formed by a substantially rigid casing 2, which has a mouth 3 closed by a lid which, in the present example, is a laminar element that is adhered to the edges of this opening by gluing. The mouth 3 and the lid make a head 4 of the capsule 1, which is opposed to the bottom 5, which will be described below.

[0164] The lid 4 is applied to the casing 2 after the latter has been filled.

[0165] The casing 2, in the present example, may have a cup shape, i.e. a truncated cone shape having a bottom 5 at the smaller base thereof and inclined walls 6, with a slight flaring, and a top at which said mouth 3 is defined by a circular top edge 7 which has a protruding border 8 or shoulder on the top circumference.

[0166] Both the bottom 5 and the top lid 4 are substantially flat, so that the casing 2, i.e., the capsule, can assume a first upright bottom-to-head arrangement, in which the casing 2 rests on the bottom 5, and a second upturned head-to-bottom arrangement, in which the casing 2 rests on the lid 4, i.e., on the circular top edge 7 to which the lid 4 is applied.

[0167] Inside the box-shaped packaging 30, the articles to be packaged are arranged on superimposed layers 38, one of which is located at the bottom of the box-shaped packaging 30.

[0168] If the articles to be packaged are different from each other, in particular if they are of two different types, each layer will be formed in such a manner that the different articles are arranged according to a predetermined pattern.

[0169] On the other hand, if the articles to be packaged are identical but arranged in different arrangements, in particular in two different arrangements, each layer will be formed in such a manner that the articles in different arrangements are arranged according to a predetermined pattern (FIGS. 13 and 14).

[0170] In the example described herein, where the articles to be packaged are capsules 1 of the form described above, they will be arranged in the box-shaped packaging 30 in two different arrangements: the aforesaid upright arrangement and the aforesaid upturned arrangement.

[0171] In a preferred version of this example, the two configurations will be arranged in each layer 38 in a checkerboard pattern, wherein each element 1 in an upright configuration is flanked laterally by elements 1 in an upturned configuration, and vice versa.

[0172] In this way, each layer 38 may assume a compact configuration in which the inclined walls 6 of adjacent capsules 1 adhere (or are very close together) to each other. It is understood, however, that the checkerboard pattern is only one of the possible patterns, which may also include honeycomb patterns, or other patterns suitable for particular shapes of the articles to be packaged.

[0173] In a preferred version of this example, the capsules 1 of superimposed layers 38 in contact with each other are arranged, within the respective pattern, with the bottoms 5 of capsules 1 of different layers in contact with each other, and with the lids 4 of capsules 1 of different layers in contact with each other. For example, this can be achieved by alternating layers 38 with a checkerboard pattern, in which the superimposed capsules 1 in upright configuration and in upturned configuration are alternated from layer to adjacent layer.

[0174] In a preferred version of this example, referring in particular to capsules 1 having a circular top edge 7 with a protruding border 8 or shoulder on the top circumference, the capsules 1 of each layer 38 are arranged staggered from each other at a spacing substantially equal to the height of the protruding border 8. In this way, in a compact configuration such as that obtained with the superposition of layers with a checkerboard pattern as described above, the bottom 5 of the capsules 1 will rest on the protruding border 8 of the adjacent capsules, so as to obtain a more compact configuration.

[0175] The above described compact configurations allow a certain number of capsules to be allocated in smaller box-shaped packagings 30, with clear advantages in terms of less space occupied.

[0176] The packaging apparatus 100 provides for both forming the box-shaped packagings 30 and filling them with articles to be packaged, particularly but not exclusively the capsules 1 described above, to obtain a finished packaging intended to be packaged for shipment.

[0177] For this reason, the packaging apparatus 100 of the present embodiment is fed with stacks of blanks and with capsules 1, which are fed in an upright configuration at an inlet section 101.

[0178] More in detail, the apparatus 100 has a first forming line which is fed at a first inlet end thereof 102 with blanks by means of a feeding station 103; this first forming line assumes a U-shaped configuration by travelling along a curve on a rotating forming carousel 125, which comprises a plurality of forming devices 150.

[0179] The feeding station 103 performs the extraction of single blanks and is connected to a folding station 104 in which the blanks are arranged in a configuration in which they are sent on a blanks conveyor 105. In the folding station 104 the blanks undergo a preliminary folding of the panels and of the flaps that form the blank. In addition, they are correctly spaced apart from each other, also in view of their format, which may vary according to the box-shaped packaging 30 which is to be made.

[0180] The blanks conveyor 105 travels through a gluing station 106 in which a plurality of hot glue guns lay appropriate glue spots on appropriate flaps of the blanks. It feeds the forming devices 150 rotating on the forming carousel 125, so that each forming device 150 intersecting the final section of the blanks conveyor 105 receives a respective blank in the correct position and already provided with the necessary glue spots.

[0181] In the curved section of the forming line, the forming devices 150 form respective box-shaped packagings 30 by means of folding operations of the panels forming the blank, adhering the flaps provided with glue to some of the panels thereof in an appropriate manner.

[0182] As will be explained in more detail below, the packaging device 400 is provided to pick and pack articles, to be packaged, fed on a first conveyor line 115, as will be explained in greater detail below.

[0183] The packaging device 400, for the purpose of packing them, inserts and lays the articles which are intended to be packaged which are conveyed onto a second conveyor line 107, also operating continuously at a predetermined speed, which is arranged in proximity to said first conveyor line 115.

[0184] On the second conveying line 107, a flow of box-shaped packagings is transported in an open configuration, apt to be filled with said articles to be packaged in layers having predetermined dimensions.

[0185] In this embodiment, the two conveyor lines 107, 115 are arranged one next to the other, developed along essentially parallel straight lines, and operating in counter-current.

[0186] As anticipated above, the packaging apparatus 100 has a second inlet section 101 at which the capsules 1 are fed in an upright configuration in a substantially unsorted manner.

[0187] At the inlet section 101, the feeder device for articles to be packaged 300 comprises an inlet line 121 which, in this example, is formed by two inlet rows 121a and 121b (FIGS. 4 and 6).

[0188] The inlet line 121 is connected to a forwarding station 112, wherein the capsules 1 are arranged on said rows 121a, 121b, and wherein a start equipment regulates the passage of the capsules 1 based on feedback that takes into account the operating state of the devices of the following stations.

[0189] The feeder device 300 comprises an upturning equipment 301 and a spacer equipment 302, so that after the forwarding station 112 the capsules 1 are spaced apart from each other, and the capsules of one of the rows 121a, 121b of the inlet line 121 are upturned, so that the capsules 1 in that row are in an upturned arrangement.

[0190] Therefore, the feeder device 300 comprises a conveying line 113 having two rows 113a, 113b of capsules 1, one next to the other, of which one conveys capsules 1 in upright arrangement and the other conveys capsules 1 in upturned arrangement.

[0191] The rows 113a, 113b of the first conveying line 113 flank a transfer station 114, wherein the capsules 1 are transferred from the first conveying line 113 to respective rows 115a, 115b of the first conveyor line 115, wherein the arrangements of single capsules 1 are arranged according to a predetermined pick-up pattern.

[0192] Between the conveying line 113 and the first conveyor line 115 there are provided, in the transfer station 114 of the feeder device 300, a pair of first transfer devices 251a, 251b realized by respective Delta-type robotic systems, which are arranged in succession, and supported by the cage frame 109 above.

[0193] Each first transfer device 251a, 251b comprises a first handling member having a first assembly of three articulated support arms 126, which performs the function of a self-moving transfer arm.

[0194] They are provided to transfer a number of capsules 1 from a single row of the conveying line 113, which will then be either all in upright arrangement or all in upturned arrangement. Each transfer device has a respective gripping device 127 with a plurality of gripping elements 128 to each grip a single capsule 1 in any arrangement.

[0195] During the transfer, the gripping elements 128 move by staggering the capsules 1 that have been picked up from each other, so that they can be arranged on the first conveyor line 115 in a position compatible with the pick-up pattern, which the first transfer devices compose during their operation.

[0196] It should be noted that, in this transfer process, the capsules 1 are transferred with a direct transfer path, in which the capsules picked up from the conveying line 113 are at least partially staggered to each other during their path and, without intermediate stops, are laid on the first conveyor line 115 according to a predetermined pattern.

[0197] The number of rows 121a, 121b of the inlet line 121 coincides with the number of the rows 113a, 113b of the conveying line 113 and the number of rows 115a, 115b of the first conveyor line 115, i.e. two.

[0198] The transfer between the two lines 107, 115 is carried out by a succession of second transfer devices 200, realized by parallel robotic systems, in particular of the Delta type, which comprise a handling member, in particular a second assembly of three articulated arms 201, and a second gripping device 202 which is controlled by said handling member, movable along three orthogonal axes, (X, Y, Z).

[0199] The second robotic transfer devices 200 are supported by the cage frame 109 above.

[0200] The possible movements of the handling member and the second gripping device 202 define, for each second transfer device, an operational volume V, shown in FIG. 7. For reasons of compactness, the second transfer devices 200 are arranged aligned on an intermediate straight line between the developments of the conveyor lines 107, 115, i.e. in proximity of at least said second conveyor line 107, in a close position, i.e. such that the respective operational volumes V are partially intersecting.

[0201] This type of robot generally has a self-learning system for working trajectories, and it is envisaged that it calculates trajectories such as not to collide with the robots at its side. However, this self-learning system may not be compatible with the required transfer rates.

[0202] For this reason, a control unit 500 of the packaging apparatus 100 controls the first transfer devices 251a, 251b and the second transfer devices 200 and, in this regard, it comprises a collection of laws of motion and relevant trajectories that determine the motion of the second transfer devices 200.

[0203] The laws of motion and the relevant trajectories are selected from a special collection so that the movements of the second transfer devices 202 do not intersect with each other, with potentially catastrophic effects, even if the operational volumes of each second transfer device 200 intersect with those of adjacent second transfer devices.

[0204] Since the movements of the second gripping devices 202 increase in both speed and complexity as the number of capsules 1 to be packaged increases for each box-shaped packaging 30, the laws of motion and the relevant trajectories are selected according to the number of layers and their predetermined dimensions at the input step in a control system that manages the packaging process in the packaging apparatus 100.

[0205] What is described herein for the second packaging devices 400 may also apply to the first transfer devices 251a, 251b, if requirements of greater compactness require that they are arranged with their respective operational volumes partially intersecting.

[0206] In order to verify that the chosen trajectories are compatible with the position of the transfer devices, a calibration step of the laws of motion and their trajectories can be provided, according to the number and mutual spacing of the transfer devices.

[0207] For example, it is possible to establish a set of laws of motion and/or trajectories for the first of the second transfer devices 200 following the path of the articles to be packaged for each task to be performed by the transfer device.

[0208] According to these first laws of motion and/or trajectories, those of the second of the transfer devices 200 will be calculated, followed by those of the third, fourth and so on.

[0209] At the end it will be possible to check that the trajectories and movement speeds of the transfer devices are carried out with inconvenience.

[0210] Each second gripping device 200 is apt to pick, from said first conveyor line 115, an entire single layer of predetermined dimensions of articles to be packaged by forming on it said predetermined pattern.

[0211] Since the layer may have a width greater than that of the two rows 115a, 115b of the first conveyor line, each second gripping device 202 may make multiple removals from the first conveyor line 115, forming for example a layer of 3x4 format, which requires two consecutive removals, or a 4x6 layer, which also requires two removals from a longer section of the first conveyor line 115.

[0212] The removals therefore precede the transfer step and the insertion step in the capsules 1, so that the insertion of a single layer 38 into a target box-shaped packaging 30 is done in a single solution.

[0213] In order to be able to manage a quantity of layers of different sizes, the second packaging device 400 comprises, for each second transfer device 200, a set of interchangeable gripping devices 202, so that each gripping device in the set is provided for the entire range of layers that the second packaging device 400 can handle.

[0214] The gripping device 202 comprises a plurality of gripping elements 203, each apt to remove a single capsule 1, which are supported by a respective support 204 protruding from a body 205 of the second gripping device 202.

[0215] In order to achieve the greatest possible compactness, the gripping elements 203 may be brought close to one another and staggered to each other by a drive equipment 206 contained in said body 205.

[0216] It should be noted that, in this embodiment, the gripping elements 203 are of two types: a first type 203′ which is provided to grip the head 4 of the capsule 1, and a second type 203″ which is provided to grip the bottom of the capsule 1 (FIG. 11).

[0217] Approaching and staggering the capsules 1 of each layer 38 grasped by the second gripping device 202 allows the insertion of the layer into a smaller box-shaped packaging 30.

[0218] In this embodiment, for each second transfer device 200, the packaging device 400 comprises an image detecting device 210, in particular a digital camera, connected to the control unit. However, it is understood that the packaging device 400 could have a number of cameras lower than the number of the second transfer devices 200, but a camera can be enslaved to more than a second transfer device 200.

[0219] In this example, the image detecting device 210 is positioned downstream of each transfer device 200 relative to the second conveyor line 107, to detect, after insertion, the conformity of the layers 38 deposited in the box-shaped packagings of the flow associated with the second conveyor line 107.

[0220] In the present example, the camera operates with a focal spacing corresponding to the spacing between its lens and the layer to be detected, so as to distinguish the presence or absence of the layer.

[0221] The camera is positioned by a fixed support 211 directly above the second conveyor line 107 of the box-shaped packagings 30, at a predetermined spacing from the respective transport surface on which said box-shaped packagings 30 is located in support.

[0222] Alternatively, each camera can send a digital image of the newly composed layer to the control unit, which compares it with an image of correct placements in a special collection: if no conformity is seen between the camera image and the expected image for a predetermined placement of a type and layer position, a non-conformity signal is output.

[0223] Therefore, in all of these variants the image detecting device 210 further comprises an image processing unit capable of analysing the images detected by the camera and comparing them with a control image, corresponding to a correct arrangement of the layer, in order to detect any discrepancies. The image processing unit is then able to output a signal for correct placing of the layer, or an alarm signal for incorrect placing of the layer, and to transmit this signal to the control unit. It should be noted that the image processing unit can be physically positioned either at the camera or at the control unit.

[0224] The packaging device 400 comprises a plurality of buffers 116, arranged in the region said first conveyor line 115, apt to receive capsules 1 therein deposited by the second transfer devices 200 in case it is impossible to insert them in the target packaging.

[0225] In particular, in combination with said image detecting devices 210 and signals provided to the control unit, the second transfer devices 200 lay the capsules subsequent to a signal of incorrect formation of a previous layer, so that the capsules are not laid in a packaging intended to be discarded.

[0226] The buffers 116 comprise support planes which are positioned close to the second transfer devices 200, on which the capsules are positioned in a predetermined arrangement.

[0227] In this respect, the support planes have respective recesses to receive a single capsule each, thus identifying said predetermined arrangement.

[0228] The control unit, by means of the second transfer devices 200, can in due course provide for the removal of the capsules 1 from said buffers 116 for their transfer to subsequent target packagings. On this occasion, forwarding station 112 will interrupt the flow of capsules 1 on the inlet line 121.

[0229] If, following a major malfunction, the space in said buffers 116 is exhausted, recovery tanks 117 are present alongside the buffers 116, apt to receive excess capsules from the second transfer devices 200.

[0230] It is understood that containers, for which a lack of conformity with the instructions in relation to the deposit of the capsules, in particular of the layers of capsules transferred by the aforesaid transfer devices 200, has been detected, whether the container has nevertheless completed its filling or whether the container is still missing layers, the capsules of which are deposited in the buffers 116, this container, at the end of its conveyor line 107, is discarded by a diverter equipment which may be of a substantially conventional type.

[0231] The discarded material will then be recovered, if possible, and reintroduced to the packaging cycle.

[0232] Once the filling is complete, the filled box-shaped packagings 30 arrive at a closing station 110. Subsequently, the closed box-shaped packagings 30 reach a discharge end 111, from where they are sent to a packaging apparatus.

[0233] To the above-described packaging apparatus and device and process for packaging articles to be packaged, a person skilled in the art may, in order to meet additional and contingent requirements, make numerous further modifications and variations, all of which are, however, within the scope of protection of the present invention as defined by the appended claims.