Container sizing method and system

Abstract

A carton sizing system (1) that has a frame (2), a controller (4), one or more cutters (51) movably mounted to the frame (2) and operatively connected to the controller (4), one or more markers (61) movably mounted to the frame (2) and operatively connected to the controller (4). The carton sizing system (1) also has a measuring system (7) that is operatively connected to the controller (4) and configured to determine, in use, the footprint of an open top carton and to determine the height of one or more objects contained within the carton. The controller (4) is configured to position the one or more cutters (51) based on the determined footprint and to cut vertical edges of the carton based on the determined height and also to position the one or more markers (61) based on the determined footprint and eight and to score or crease vertical walls of the carton between the vertical edges to at least partially define foldable panels.

Claims

1. A carton sizing system for sizing open top cartons having different widths and lengths, the system comprising: a frame; a controller; one or more cutters movably mounted to the frame and operatively connected to the controller, the one or more cutters being movable in a first horizontal direction, a second horizontal direction perpendicular to the first horizontal direction, and a vertical direction perpendicular to the first and second horizontal directions such that the same cutter(s) can be repositioned to accommodate different carton widths and lengths; one or more markers movably mounted to the frame, each marker being mounted to a robotic arm and comprising a pair of marker elements for compressing and marking a carton wall therebetween to score or crease the carton wall, the robotic arm(s) being operatively connected to the controller and configured to move, in use, the marker element pair mounted thereto in the first horizontal direction, the second horizontal direction, and the vertical direction such that the same marker element pair can be repositioned to accommodate different carton widths and lengths; and a measurement system operatively connected to the controller and configured to determine, in use, a width and a length of an open top carton and to determine a height of one or more objects contained within the open top carton; wherein the controller is configured to: move the one or more cutters and the one or more marker element pairs in the first horizontal direction based on the determined width of the open top carton; move the one or more cutters and the one or more marker element pairs in the second horizontal direction based on the determined length of the open top carton; cause the one or more cutters to cut vertical edges of the open top carton based on the determined height of the one or more objects contained within the open top carton; cause the robotic arm(s) to move the one or more marker element pairs in the vertical direction based on the determined height of the one or more objects contained within the open top carton; and cause the one or more marker element pairs to score or crease vertical walls of the open top carton between the vertical edges to at least partially define foldable flaps or panels.

2. Carton sizing system according to claim 1, wherein each of the one or more cutters is mounted to a robotic arm, the robotic arm(s) to which the marker(s) and cutter(s) are mounted each comprising an articulated arm movable in three or more axes.

3. Carton sizing system according to claim 1, wherein each of the one or more cutters is mounted to a robotic arm of a cartesian robot ora robotic gantry system.

4. Carton sizing system according to claim 1, wherein each of the one or more cutters comprises a blade movably mounted to a support and a guard mounted to the support, wherein the blade is movable between a deployed position in which a corner or edge of the blade is exposed for cutting and a retracted position in which it is at least partially covered or concealed by or within the guard.

5. Carton sizing system according to claim 1, wherein the controller is configured to position, in use, the cutter or one of the cutters to cut a first vertical edge of the open top carton and then to position the same cutter to cut a second vertical edge of the same open top carton, different from the first vertical edge.

6. Carton sizing system according to claim 5, wherein the controller is configured to position, in use, the same cutter to cut each of the vertical edges of the same open top carton in sequence.

7. Carton sizing system according to claim 1, wherein the robotic arm(s) comprise part of a cartesian robot or a robotic gantry system.

8. Carton sizing system according to claim 1, wherein the pair of marker elements comprises a blade element and an anvil element against which the blade element may be urged to create a crease or score mark or line, the blade element or the anvil element having a width which is less than that of a wall of the open top carton to be creased such that each open top carton wall to be creased is creased multiple times.

9. Carton sizing system according to claim 1, wherein the measurement system comprises one or more sensors for determining, in use, one or more dimensions of the open top carton.

10. Carton sizing system according to claim 1, wherein the controller is configured to position, in use, the marker or one of the markers to score or crease a first vertical wall of the open top carton and then to position the same marker to score or crease a second vertical wall of the same open top carton, different from the first vertical wall.

11. Carton sizing system according to claim 10, wherein the controller is configured to position, in use, the same marker to score or crease each of the vertical walls of the same open top carton in sequence.

12. Carton sizing system according to claim 10, wherein the controller is configured to position, in use, the same marker to score or crease different portions of the first or each vertical wall of the same open top carton in sequence.

13. Carton sizing system according to claim 1, wherein the measurement system comprises an imaging system configured to capture, in use, one or more images from one or more positions or angles and to determine or measure from each of the one or more captured images one or more features or dimensions of the open top carton or the one or more objects contained with the open top carton.

14. Carton sizing system according to claim 13, wherein the imaging system is configured to determine or measure from each of the one or more captured images a height of one or more objects contained within the open top carton and a width and length of the open top carton.

15. Carton sizing system according to claim 13, wherein the controller is configured to determine or calculate one or more required cutter positions and one or more required cutter orientations for cutting each of the vertical edges of the open top carton based on the determined or measured feature(s) or dimension(s) of the open top carton or the one or more objects contained within the open top carton.

16. Carton sizing system according to claim 13, wherein the controller is configured to determine or calculate one or more required marker positions and one or more required marker orientations for scoring or creasing each of the vertical walls of the open top carton based on the determined or measured feature, the determined or measured features, the determined or measured dimension, or the determined or measured dimensions of the open top carton or the one or more objects contained within the open top carton.

17. A method of forming a carton comprising the steps of: determining a width and a length of an open top carton using a measurement system: determining a height of one or more objects contained within the open top carton using the measurement system; automatically determining a position of vertical edges of the open top carton based on the determined width and length of the open top carton using a controller: automatically determining a required height of the open top carton based on the determined height of the one or more objects using the controller; causing the controller to: move one or more cutters in a first horizontal direction based on the determined width of the open top carton and in a second horizontal direction, perpendicular to the first horizontal direction, based on the determined length of the open top carton to a position adjacent each of the vertical edges; cause the one or more cutters to cut each of the vertical edges between an upper edge of the open top carton and a position at or adjacent a required carton height based on the determined height of the one or more objects contained within the open top carton; cause each of one or more robotic arms to move a respective marker element pair in the first horizontal direction based on the determined width of the open top carton and in the second horizontal direction based on the determined length of the open top carton; and score or crease vertical walls between the vertical edges of the open top carton using the one or more marker element pairs by compressing and marking each vertical wall therebetween at a position at or adjacent the required carton height such that one or more foldable flaps or panels are defined in the vertical walls.

18. A carton sizing system comprising: a frame; a controller; one or more cutters movably mounted to the frame and operatively connected to the controller, each of the one or more cutters being movable in three or more axes such that the same cutter(s) can be repositioned to accommodate different carton widths and lengths; one or more markers movably mounted to the frame, each marker being mounted to a robotic arm and comprising a pair of opposed marker elements, the robotic arm(s) being operatively connected to the controller and configured to move, in use, the marker element pair mounted thereto in three or more axes such that the same marker element pair can be repositioned to accommodate different carton widths and lengths; and one or more sensors operatively connected to the controller and configured to determine, in use, a width and a length of an open top carton and to determine a height of one or more objects contained within the open top carton; wherein the controller is configured to: move the one or more cutters along the three axes based on the determined width and length of the open top carton and based on the determined height of the one or more objects contained within the open top carton; cause the one or more cutters to cut vertical edges of the carton based on the determined height of the one or more objects contained within the open top carton; and cause the one or more marker element pairs to score or crease vertical walls of the open top carton between the vertical edges by compressing and marking each vertical wall therebetween to at least partially define foldable flaps or panels.

19. Carton sizing system according to claim 18, wherein each of the one or more cutters is mounted to a robotic arm, the robotic arm(s) to which the marker(s) and cutter(s) are mounted each comprising an articulated arm movable in three or more axes.

20. Carton sizing system according to claim 18, wherein each of the one or more cutters is mounted to a robotic arm, the robotic arm(s) to which the marker(s) and cutter(s) are mounted each comprising a robotic arm of a cartesian robot or a robotic gantry system.

Description

(1) Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:

(2) FIG. 1 is a perspective view of a carton sizing system according to one embodiment of the invention with the front guards omitted for illustrative purposes;

(3) FIG. 2 is a partial front view of the device of FIG. 1 showing the cutting and creasing stations;

(4) FIG. 3 is a more detailed view of the cutting station of FIGS. 1 and 2;

(5) FIG. 4 is a view similar to that of FIG. 3 with the carton omitted to show the cutter;

(6) FIG. 5 is a more detailed view of the creasing station of FIGS. 1 and 2 with the carton omitted to show the marker;

(7) FIG. 6 is a more detailed view of the marker of FIG. 5;

(8) FIG. 7 is a detailed view of a gantry robot positioning system;

(9) FIG. 8 is a perspective view of a cutting station according to an alternative embodiment; and

(10) FIG. 9 is a perspective view of a creasing station according to an alternative embodiment.

(11) Referring now to the Figures, there is shown a carton sizing system 1 according to one embodiment of the invention for adapting the size or configuration of a carton 10 partially filled with one or more products (not shown). The carton sizing system 1 includes a frame 2, a belt conveyor 3, a controller 4 housed in an upper portion 20 of the frame 2, a cutting station 5, a creasing station 6 and a vision system 7.

(12) The frame 2 includes a plurality of frame members 21 interconnected to form a rectangular frame assembly 2 with four adjustable feet 22 at its outer corners and a plurality of panels 23a, 23b extending across the frame members to enclose the carton sizing system 1. The frame 2 includes two sections, namely a cutting section 24 and a creasing section 25, with a mounting pad 26 secured to the uppermost frame members 21 and extending across the length of the frame 2 to form a roof thereof. The conveyor 3 is mounted to the frame 2 at a vertically raised position and extends across and through the short sides of the enclosure to provide an infeed section 30 and an outfeed section 31, each of which is enclosed by a respective inverted U-shaped guard 32, 33 extending from a respective end panel 23a of the frame 2 to a respective end of the conveyor 3.

(13) The cutting station 5 is housed within the cutting section 24 of the frame 2 and includes a six axis articulated robotic arm 50 with a cutter 51 mounted to the end thereof such that the position and orientation of the cutter 51 can be varied to suite an infinite number of configurations. The robotic arm 50 is secured to the underside of the mounting pad 26 and extends downwardly therefrom into the cutting section 24 of the frame 2 toward the conveyor 3.

(14) The cutter 51, shown more clearly in FIGS. 3 and 4, includes a hook shaped blade 52 pivotally mounted to a support block 53 and a pair of guard members 54 secured to the support block 53 and that extend downwardly therefrom on either side of the blade 52. The blade 52 is pivotable between a deployed position in which the front hook and cutting edge of the blade 52 are exposed for cutting and a retracted position (not shown) in which the hook and cutting edge of the blade 52 are concealed and located between the guard members 54. The blade 52 in this embodiment includes an integral extension arm 55 that extends from a rear portion of the blade 52 substantially orthogonally with respect to the cutting edge thereof. The cutter 51 also includes an pneumatic cylinder 56 for moving the blade 52 between the retracted and deployed positions. The cylinder 56 is pivotally connected to the support block 53 at one end and to the extension arm 55 at its other end. The cylinder 56 is operatively connected to and controlled by the controller 4.

(15) The creasing station 6 is housed within the creasing section 25 of the frame 2 and includes a six axis articulated robotic arm 60 with a creaser 61 mounted to the end thereof such that the position and orientation of the creaser 61 can be varied to suite an infinite number of configurations. The robotic arm 60 is secured to the underside of the mounting pad 26 and extends downwardly therefrom into the creasing section 25 of the frame 2 toward the conveyor 3.

(16) The creaser 61, shown more clearly in FIGS. 5 and 6, includes a blade element 62 with a creasing edge 63, an anvil element 64 with a depression 65 for receiving the creasing edge 63 of the blade element 62 and a base 66. The creasing edge 63 of the blade element 62 is dull in this embodiment for creasing rather than scoring by crushing a carton wall to be creased against the anvil element 64 to create a crease line. The creaser also includes an L-shaped blade arm 67 pivotally mounted at its corner to the base 66 and having an end that the blade element 62 is mounted, an anvil arm 68 fixed or secured relative to the base 66 with an end to which the anvil element 64 is mounted and a pneumatic cylinder 69 for moving the blade arm 67 relative to the anvil arm 68 and base 66 to selectively separate or bring together the creasing edge 63 and depression 65. The cylinder 69 is pivotally connected to an extension portion of the anvil arm 68 that extends orthogonally from the anvil element 64 and to the other end of the L-shaped blade arm 67.

(17) The vision system 7 includes first and second cameras 70 and 71 for capturing images of cartons 8 entering into the infeed section 30 of the conveyor 3 from different respective angles. The first camera 70 is mounted on top of the inverted U-shaped guard 32 of the infeed section 30 of the conveyor 3 and arranged to take an image of the top of a carton 8 as it enters into the infeed section 30 of the conveyor 3. The second camera 71 is mounted on one side of the inverted U-shaped guard 32 of the infeed section 30 of the conveyor 3 and arranged to take an image of the side of a carton 8 as it enters into the infeed section 30 of the conveyor 3.

(18) The vision system 7 is configured to determine from the captured images the height of the contents (not shown) of the carton 8 as well as the width, length and height of the carton 8. These parameters are then sent to the controller 4, which calculates each of the four required start positions and orientations and cutting paths of the cutter 51 to cut the requisite portions of the vertical edges 80 of the carton 8. The controller 4 also calculates each of the required creasing positions and orientations for the creaser 61 to crease the vertical walls 81 of the carton 8.

(19) In use, a partially filled carton 8 enters into the infeed section 30 of the conveyor, images are captured by the cameras 70, 71 of the vision system 7 and the aforementioned parameters are sent to the controller 4, which then calculates automatically the aforementioned start positions, orientations and cutting paths. The carton 8 advances along the conveyor 3 to the cutting station 5 and the controller 4 sends the requisite command signals to the robotic arms 50, 60. With the carton 8 in the cutting station 5, the cutter arm 50 moves the cutter 51 to the first start position and orientation, deploys the cutting blade 52 and cuts the first vertical edge 80. The cutter arm 50 then moves the cutter 51 to each of the other vertical edges and cuts them in turn. The cutter arm 50 then retracts out of the carton 8, which advances to the creasing station 6.

(20) The creaser 61 is moved by the creaser arm 60 to the first start position and orientation, wherein the blade element 62 is positioned adjacent an internal surface of a first of the carton walls 81 between a first two of the vertical edges 80 with the anvil element 64 adjacent a corresponding external surface of the first carton wall 81. The cylinder 69 then actuates the creaser arms 67, 68 to bring the blade and anvil elements 62, 64 together to crease the portion of the wall 81 between them. It will be appreciated that the width of the creaser 61 is significantly less than the width of the carton wall 81 and so the creaser 61 is then operated to separate the blade and anvil elements 62, 64, the creaser 61 is then moved along to the next portion of the wall 81 and the creasing process is repeated. This process is repeated until the crease is formed across the whole of the wall 81 and is then repeated for each of the other carton walls 81. The creaser arm 60 then retracts out of the carton 8, which advances to the outfeed section 31 to be sent to a folding and gluing and/or taping and/or strapping station (not shown).

(21) Referring now to FIG. 7, there is shown a four axis gantry robot positioning system 200 having a vertical support 202 and housing 250 for adjusting the position of the cutter(s) (not shown) and/or creasers (not shown). The arms (not shown) of cutter(s) (not shown) and/or creasers (not shown) are connected to the positioning system 200 by a rotatable mount 240 that is connected to the vertical support 202 within the frame 2. The rotatable mount 240 allows the position of the cutter (not shown) or creaser (not shown) to be rotated or twisted in use.

(22) The vertical support 202 and housing 250 are mounted on a first pair of guide rails 210a, 210b such that, in use, the position of the vertical support 202 (and therefore that of the cutter or creaser arm) may be adjusted in a first, vertical, axis.

(23) The positioning system 200 also has a second pair of guide rails 220a, 220b, along which the position of the vertical support 202 and housing 250 (and therefore that of the cutter or creaser arm) may be adjusted in a second axis that is perpendicular to the first axis.

(24) The positioning system 200 has a further, third, pair of guide rails 230a, 230b, along which the position of the vertical support 202, housing 250 and second pair of guide rails 220a, 220b may be adjusted in a third axis. This enables, in use, the position of the cutter or creaser arm (not shown) to be adjusted in a forward or backward direction relative to the direction of travel of the belt conveyor (not shown).

(25) Referring now to FIG. 8, there is shown an alternative cutter 510 that is suitable for cutting the corners of a carton 8. The cutter 510 includes a blade 511 pivotally mounted to a first arm portion 512 and an anvil element 514 pivotally mounted to a second arm portion 516. The anvil element 514 has a depression 515 for receiving the blade 511 and the cutter 510 is operated by a first actuator 513, while the anvil element 514 is operated by a second actuator 517. The cutter 510 is mounted to a rotating joint 502 such that it may be oriented in any direction. The actuators 513, 517 and the rotating joint 502 are operatively connected to the controller (not shown). In use, the blade 511 is positioned within the box or carton (not shown) to be cut, and the anvil element 514 is positioned on the outside of the box or carton (not shown). Actuators 513 and 517 are operable either individually or in tandem in order to close the blade 511 and anvil element 514 together, thereby cutting any box or carton (not shown) positioned between the two parts.

(26) Referring now to FIG. 9, there is shown an alternative creaser 610. The creaser 610 comprises first and second rollers 620 and 640 mounted to respective first and second arm portions 622, 642. A first roller 620 is rotatably mounted to a fixed extension 622a of the first arm portion 622 and includes a creasing edge 621. A second roller 640 is rotatably mounted to a movable extension 642 that is pivotally mounted to the second arm portion 642 and operated by an actuator 643. The second roller 640 provides an anvil member with a depression 641 for receiving the creasing edge 621 of the first roller 620. The creasing edge 621 of the roller 620 is dull in this embodiment for creasing rather than scoring by crushing a carton wall to be creased against the anvil element 641 to create a crease line. The actuator 643 is operatively connected to the controller (not shown) and drives the anvil member 640 toward the roller 620 for effecting a crease. Both the roller 620 and anvil member 640 are circular and rotatable, such that in use the two may be brought together to form a crease and moved along a carton 8 to form a single crease without requiring repeated opening and closing motions. In a further alternative embodiment, the roller 620 has a series of sharp blades (not shown) about its circumference at regular intervals so that as the blade is run along the carton surface it creates a perforated line.

(27) It will be appreciated by those skilled in the art that several variations to the embodiments described herein are envisaged without departing from the scope of the invention. For example, while the marker of this embodiment is a creaser 61 it may be replaced with a scorer or scoring means, for example a sharp blade (not shown) that may include a plurality of teeth (not shown) for creating perforations in the carton 10. Additionally or alternatively, the measuring means need not be provided by a vision system 7. It may, for example comprise one or more sensors for measuring or determining, in use, one or more dimensions of the container or carton or its contents. The container need not be a carton 8, it may be any other suitable container for which the present invention may be useful.

(28) The system 1 may also include any one or more of a carton blank feeding station, an erecting station, a folding and/or closing and/or gluing and/or taping station, a strapping station, a stacking station and a palletising station.

(29) It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.

(30) The above exemplary embodiments of the present invention have been described with reference to numerous directional terms such as top, bottom, side, end, upper, inwardly, upwardly, vertical, etc. It is to be understood that these directional terms are used purely for the benefit of aiding clarity of the description of the exemplary embodiments and are in no way limiting to the scope of the disclosure.