Method and system for creating custom-sized cardboard blanks for packagings and method and system for automatically packaging shipment sets in boxes
10752387 ยท 2020-08-25
Assignee
Inventors
- Melle Jonker (Drachten, NL)
- Eelke Visser (Drachten, NL)
- Valery Grushka (Drachten, NL)
- Jelle Wiersma (Drachten, NL)
- Peter van Eijk (Drachten, NL)
Cpc classification
B65B2210/04
PERFORMING OPERATIONS; TRANSPORTING
B31B2100/002
PERFORMING OPERATIONS; TRANSPORTING
B31B50/006
PERFORMING OPERATIONS; TRANSPORTING
B65B5/06
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65B59/00
PERFORMING OPERATIONS; TRANSPORTING
B31B50/00
PERFORMING OPERATIONS; TRANSPORTING
B65B5/06
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A system for creating custom-sized cardboard blanks for folding packagings comprises a first and at least a second supply for fanfold cardboard, a control unit (e.g., microprocessor) that calculates, based on order information regarding the desired minimum dimensions of a current packaging, under predefined optimization criteria a first blank layout for folding the packaging, said blank layout comprising a leading edge and an ending edge and transverse and longitudinal crease lines dividing the blank having a desired length and width into panels, defines, based on predefined criteria, areas around the transverse crease lines and the leading and ending edges, in which no transverse folds from fanfolding the cardboard should be present, sensors communicatively coupled with said control unit that sense information indicative of a presence of transverse folds in cardboard, a cutter to cut-off the piece of cardboard from the first or the second web and form the desired blank.
Claims
1. A method for creating custom-sized cardboard blanks for folding packagings from a piece of corrugated cardboard cut-off from a web of fanfold cardboard, said cardboard having transverse folds from fanfolding, the method comprising: calculating, based on order information regarding the desired minimum dimensions of a current packaging, under predefined optimization criteria a first blank layout for folding the packaging, said blank layout comprising a leading edge and an ending edge and transverse and longitudinal crease lines dividing a blank having a desired length and width into panels, said transverse crease lines separate from said transverse folds, defining, based on predefined criteria, areas around the transverse crease lines, the leading edge and the ending edge, in which none of the transverse folds should be present, obtaining information on the presence of said transverse folds in cardboard ready to be cutoff from a first web of fanfold cardboard and checking, if said transverse folds are present in said areas, if none of the transverse folds are present in said areas, cutting-off a piece of cardboard and forming the desired blank, and if one of the transverse folds is present in at least one of said areas, performing at least one of the following steps: A) calculating a second blank layout for folding the same packaging, said second layout comprising transverse and longitudinal crease lines at different positions than the first layout, B) enlarging at least one of the panels by shifting a respective transverse crease line and the ending edge, C) obtaining information on the presence of said transverse folds in cardboard ready to be cut-off from at least one additional web of fanfold cardboard, and, if none of the transverse folds are present in said areas, cutting-off a piece of cardboard of the desired length from the at least one additional web.
2. The method according to claim 1, wherein if one of the transverse folds is present in at least one of said areas, the method further comprises: D) cutting-off a certain amount of the cardboard ready to be cut-off from the web of fanfold cardboard to be used for the blank to eliminate the transverse fold and/or to shift the position of the transverse folds with respect to the leading edge of the web.
3. The method according to claim 1, wherein if one of the transverse folds is present in at least one of said areas further comprising: E) calculating based on order information of a subsequent packaging at least a first blank layout for folding the packaging, and checking, if any of the transverse folds in the cardboard ready to be cut-off would interfere with the transverse crease lines and the leading and ending edges in this layout and, if not, processing the subsequent packaging first.
4. The method according to claim 1, wherein if one of the transverse folds is present in at least one of said areas, the method further comprises evaluating under predefined optimization criteria which of said steps is performed.
5. The method according to claim 1, wherein the areas, in which none of the transverse folds should be present, have different extensions in the longitudinal direction of the blank layout.
6. The method according to claim 1, wherein defining areas around the transverse crease lines, the leading edge and the ending edge, in which none of the transverse folds should be present includes assigning different priorities by a customer among priorities including minimized volume and maximized stability of the packaging for defining areas, taking these priorities into account upon deciding; which acts shall be performed in case one of the transverse folds is present in said areas.
7. The method according to claim 1, wherein obtaining information on the presence of the transverse folds in the cardboard includes obtaining information on fold orientation in the fanfold stack and taking the fold orientation into account upon deciding, which acts shall be performed in case one of the transverse folds is present in said areas.
8. The method according to claim 1, further comprising: placing a shipment set to be packaged on one of the panels of the blank forming a bottom panel of a box, and folding the remaining panels around the shipment set.
9. The method according to claim 8, further comprising: turning the shipment set to be packaged by 90 in a plane parallel to the blank.
10. The method according to claim 8, further comprising: preparing two shipment sets on parallel arranging stations, determining a blank layout for both shipment sets, determining based on information about said transverse folds present in cardboard ready to be cut-off from a web of fanfold cardboard, which shipment set shall be packaged first, and transporting the shipment set to be packaged first onto a respective cardboard blank produced first.
11. A system for creating custom-sized cardboard blanks for folding packagings from a piece of corrugated cardboard cut-off from a web of fanfold cardboard, said cardboard having transverse folds from fanfolding, the system comprising: a first and at least a second supply for supplying webs of fanfold cardboard, a central control unit adapted for: calculating, based on order information regarding the desired minimum dimensions of a current packaging, under predefined optimization criteria a first blank layout for folding the packaging, said blank layout comprising a leading edge and an ending edge and transverse and longitudinal crease lines dividing a blank having a desired length and width into panels, said transverse crease lines separate from said transverse folds, and defining, based on predefined criteria, areas around the transverse crease lines and the leading and ending edges, in which none of the transverse folds should be present, sensors communicatively coupled with said control unit for obtaining information on the presence of transverse folds in cardboard ready to be cut-off from the first web, sensors communicatively coupled with said control unit for obtaining information on the presence of transverse folds in cardboard ready to be cut-off from the second web, and structure for cutting-off the piece of cardboard from the first or the second web and forming the desired blank, said central control unit further adapted for: checking, if one of the transverse folds would be present in at least one of said areas if the piece of cardboard would be cut-off from the first web and performing, in case such transverse fold would be present, at least one of the following steps: A) calculating a second blank layout for folding the same packaging, said second layout comprising transverse and longitudinal crease lines at different positions than the first layout, B) enlarging at least one of the panels by shifting a respective transverse crease line and the ending edge, C) checking, if one of the transverse folds would be present in at least one of said areas if the piece of cardboard would be cut-off from the second web, and, if none of the transverse folds are present in said areas, cutting-off the piece of cardboard from the second web.
12. The system according to claim 11, further comprising: structure for transporting a shipment set onto the blank, and structure for folding a box from the blank around said shipment set, wherein the blank is produced by: calculating, based on order information regarding the desired minimum dimensions of a current packaging, under predefined optimization criteria a first blank layout for folding the packaging, said blank layout comprising a leading edge and an ending edge and transverse and longitudinal crease lines dividing the blank having a desired length and width into panels, said transverse crease lines separate from said transverse folds, and defining, based on predefined criteria, areas around the transverse crease lines, the leading edge and the ending edge, in which none of the transverse folds should be present, obtaining information on the presence of said transverse folds in cardboard ready to be cutoff from a first web of fanfold cardboard and checking, if said transverse folds are present in said areas, if none of the transverse folds are present in said areas, cutting-off a piece of cardboard and forming the desired blank, and if one of the transverse folds is present in at least one of said areas, performing at least one of the following steps: A) calculating a second blank layout for folding the same packaging, said second layout comprising transverse and longitudinal crease lines at different positions than the first layout, B) enlarging at least one of the panels by shifting a respective transverse crease line and the ending edge, C) obtaining information on the presence of said transverse folds in cardboard ready to be cut-off from at least one additional web of fanfold cardboard, and, if none of the transverse folds are present in said areas, cutting-off a piece of cardboard of the desired length from the at least one additional web.
13. The system according to claim 12, further comprising: at least two arranging stations for arranging shipment sets to be packaged in parallel, and at least one merge conveyor for transporting shipment sets from the arranging station to a box forming station for folding a box around the respective shipment set.
14. The system according to claim 12, further comprising structure for turning the shipment set to be packaged by 90 in a plane parallel to the blank.
15. The system according to claim 11, wherein said central control unit is further adapted, such that if one of the transverse folds is present in at least one of said areas, for: D) actuating the structure for cutting-off the piece of cardboard to cut-off a certain amount of the cardboard ready to be cut-off from the web of fanfold cardboard to be used for the blank to eliminate the transverse fold and/or to shift the position of the transverse folds with respect to the leading edge of the web.
16. The system according to claim 11, wherein said central control unit is further adapted, such that if one of the transverse folds is present in at least one of said areas, for: E) calculating based on order information of a subsequent packaging at least a first blank layout for folding the packaging, and checking, if any of the transverse folds in the cardboard ready to be cut-off would interfere with the transverse crease lines and the leading and ending edges in this layout and, if not, processing the subsequent packaging first.
17. The system according to claim 11, wherein said central control unit is further adapted, such that if one of the transverse folds is present in at least one of said areas, for evaluating under predefined optimization criteria which of said steps is performed.
18. The system according to claim 11, wherein said central control unit is further adapted to define areas around the transverse crease lines, the leading edge, and the ending edge, in which none of the transverse folds should be present by assigning different priorities including minimized volume and maximized stability of the packaging, taking these priorities into account upon deciding which steps shall be performed in case one of the transverse folds is present in said areas.
19. The method according to claim 11, wherein the sensors are communicatively coupled with said control unit for obtaining information on the presence of the transverse folds in the cardboard to obtain information on fold orientation in the fanfold stack and taking the fold orientation into account upon deciding, which steps shall be performed in case one of the transverse folds is present in said areas.
Description
BRIEF DESCRIPTION OF THE DRAWING
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DESCRIPTION OF PREFERRED EMBODIMENTS
(11) In order to better understand the advantages of the invention,
(12) The length of the box to be folded from blank 12 is determined in this layout by the length L.sub.BP of the bottom panel 14 (which corresponds to the length of the top panel 16 and the respective side panels 24, 26, 28 and 30). The width of the box is determined by the width W.sub.BP of the bottom panel 14 (which corresponds to the width of top panel 16 and the first, second and third end panels 18, 20, 22). The height of the box is determined by the length L.sub.EP of the second end panel 20 (which in this embodiment corresponds to the length of the first end panel 18).
(13) In a system using a blank 12 as shown in
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(15) As previously mentioned, due to the nature of double-faced corrugated cardboard, fanfolding it leads to transverse crease lines having a structure that amongst others depends on the position, where the cardboard is folded.
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(17) While the crease lines 124 and 126 in the schematic drawing appear to be two parallel straight lines, in fact these lines may, depending on the thickness of the cardboard, be comprised of three slightly offset sections giving the end panels 104, 106 a different width W.sub.EP than the width W.sub.BP of the bottom panel 104.
(18) In the shown embodiment, the length L.sub.BP of the bottom panel 104 determines the length L of a box to be folded, while the length L.sub.EP of the end panels 106, 108 determines the height H of the box to be folded.
(19) As schematically indicated by the strip 140 shown beneath the blank, to each transverse crease line and in this case also to the leading edge 136 and the ending edge 138, an area 142 is defined, indicated by the black rectangles, in which no transverse folds should be present. Next to the leading edge 136, no transverse fold should be present in order to facilitate gripping the end panel 106 upon automated folding. Likewise, behind ending edge 138, where the next blank will begin, no transverse fold should be present, as this will become a transverse fold near the leading edge of the next blank. Behind transverse crease line 122 and before transverse crease line 120, no transverse folds should be present. As schematically indicated in
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(22) If a blank having the layout 160 would be cut as indicated in
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(25) Once arranged, the item(s) forming a shipment set are transported with the first respective first conveyors 182, 184 onto respective second conveyors 190, 192 through respective laser scanner 194, 196 for determining the maximum outer dimensions of the arrangement, which allows in a manner known per se to calculate the dimensions of a respective box needed for packaging the shipment set. As set out above, a control unit (not shown) calculates box layouts necessary for forming packagings for both shipment sets and determines which blank layout shall be produced first based on information on the presence of transverse folds in cardboard ready for being used for making the blanks. Of course, such system may be provided with more than one supply unit for supplying cardboard, which gives further flexibility in optimizing the blanks while avoiding the presence of transverse folds in certain areas. As two separate conveyors 182, 190 respectively 184, 192 are associated with each arranging station, new items 186, 188 can already be received for being arranged while already prepared and scanned arrangements 198, 200 schematically indicated in
(26) As schematically indicated in
(27) The systems 180, 180 or an alternative system for automatically packaging shipment sets in custom-sized cardboard boxes, may, in addition to a first and at least a second supply for supplying web of fanfold cardboard, a central control unit adapted for performing the aforementioned acts, sensors communicatively coupled with said control unit for obtaining information on the presence of transverse folds in cardboard ready to be cut-off from the first web and from the second web, structure for cutting-off the piece of cardboard from the first or the second web and forming the desired blank, structure for transporting a shipment set onto a blank produced according to one of the aforementioned method, and structure for folding a box from the blank around said shipment set also comprise structure for turning the shipment set to be packaged by 90 in a plane parallel to the blank, which would allow to use a blank layout, in which the width and length dimension of the bottom panel are interchanged.
(28) Various embodiments of the devices and/or processes via the use of block diagrams, schematics, and examples have been set forth herein. Insofar as such block diagrams, schematics, and examples contain one or more functions and/or operations, it will be understood by those skilled in the art that each function and/or operation within such block diagrams, flowcharts, or examples can be implemented, individually and/or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof. In one embodiment, the present subject matter may be implemented via integrated circuits, as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more control units (i.e., controllers or other processors (e.g., microcontrollers, microprocessors, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), digital signal processors (DSPs), graphics processing units (CPUs) programmable logic controllers (PLCs)) as one or more programs running on one or more processors, as firmware, or as virtually any combination thereof, and that designing the circuitry and/or writing the code for the software and or firmware would be well within the skill of one of ordinary skill in the art in light of this disclosure.
(29) When logic is implemented as software and stored in memory, one skilled in the art will appreciate that logic or information, can be stored on any computer- or processor-readable medium for use by or in connection with any computer and/or processor related system or method. In the context of this document, a memory is a computer- or processor-readable medium that is an electronic, magnetic, optical, or other another physical device or means that contains or stores a computer and/or processor program. Logic and/or the information can be embodied in any computer readable medium for use by or in connection with an instruction execution system, apparatus, or device, such as a computer-based system, processor-containing system, or other system that can fetch the instructions from the instruction execution system, apparatus, or device and execute the instructions associated with logic and/or information. In the context of this specification, a nontransitory computer- or processor-readable medium can be any nontransitory physical structure can store, communicate, propagate, or transport the program associated with logic and/or information for use by or in connection with the instruction execution system, apparatus, and/or device. The computer- or processor-readable medium can be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device. More specific examples (a non-exhaustive list) of the computer- or processor-readable medium would include the following: a portable computer diskette (magnetic, compact flash card, secure digital, or the like), a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM, EEPROM, or Flash memory), and a portable compact disc read-only memory (CDROM). Note that the computer- or processor-readable medium could even be another suitable nontransitory medium upon which the program associated with logic and/or information is stored.
(30) In addition, those skilled in the art will appreciate that certain mechanisms of taught herein are capable of being distributed as a program product in a variety of forms, and that an illustrative embodiment applies equally regardless of the particular type of signal bearing media used to actually carry out the distribution. Examples of signal bearing media include, but are not limited to, the following: recordable type media such as floppy disks, hard disk drives, CD ROMs, digital tape, and computer memory.
(31) The various embodiments described above can be combined to provide further embodiments.
(32) From the foregoing it will be appreciated that, although specific embodiments have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the teachings. Accordingly, the claims are not limited by the disclosed embodiments.