Blank Separating Device, Corresponding Packaging Machine, and Method for Producing Separated Blanks from a Stack

Abstract

In order to no longer have to store blanks (Z) separately in a blank magazine (20) and frequently refill the magazine manually, stamping sheets (SB) which contain a plurality of blanks (Z) that are still connected together by means of micro-connections (M) are delivered without stamped grids in a stacked manner on a Euro-pallet (14) for example, and the blanks (Z) are removed individually from the uppermost stamping sheet (SB) by a blank separating device (50) using a gripping tool (2), in particular by means of a separating robot (1) and a gripping tool (2) attached thereto.

Claims

1. Blank separating device (50) for separating flat blanks (Z), in particular of cardboard material, for producing dimensionally stable outer packaging such as cardboard boxes (K), with a supply station (3) in which an, in particular vertical, stack (13) of, in particular, plate-shaped stamping sheets (SB), each having a plurality of blanks (Z) lying in one plane, adjoining one another and connected to one another via predetermined tearing points (M), in particular micro-connections (M), is kept, a robot (1) for removing at least one blank of the uppermost stamping sheet (SB), in particular from the supply station (3), a controller (50*) for controlling at least all moving parts of the blank separating device (50), characterised in that the robot (1) is designed as a separating robot with a corresponding gripping tool (2) with which it is capable of gripping only one or a group of several, in particular still connected, blanks (Z) from the interconnected blanks (Z) of the stamping sheet (SB) and separating them from the at least one adjacent blank (Z) of the remainder of the uppermost stamping sheet (SB) by lifting them off the stack and thereby tearing off the desired tear points (M), at least one hold-down (15) is provided for preventing the remaining punch sheet (SB) from lifting off when the blank (Z) gripped by the separating robot (1) is lifted. (Tool:).

2. Blank separating device according to claim 1, characterised in that the gripping tool (2) has as gripper one or more top-side grippers, in particular adhesion grippers or suckers (4), arranged in particular in a horizontal gripping plane (4), the position of the suction cups (4) on the tool base body (2A) is adjustable, in particular when viewed from above, is radially adjustable, in particular with respect to its central area (2Az).

3. Blank separating device according to claim 2, characterised in that each top gripper (4) is attached to a radially extending suction arm (5) and is either adjustable in position along the suction arm (5) or is located at the end of the suction arm (5) and the suction arm (5) is adjustable in length or each top gripper (4) is adjustably mounted in or on a radial suction guide formed on the tool base body (2A) or the tool base body (2A) comprises a suction cup support plate (6) with a plurality of fastening devices for top grippers (4) arranged in particular radially as well as circumferentially around the central area of the base body (2A).

4. Blank separating device according to claim 2, characterised in that the robot (1) or the gripping tool (2) is designed in such a way that, after activation of the top grippers (4), the suction plane (4) can be adjusted to an oblique position relative to the horizontal (11+12) and/or the gripping tool (2) is designed in such a way that the individual top-side grippers (4) can be activated in a controlled manner in a specific sequence, individually or in groups and/or the robot tool (2) is designed in such a way that top side grippers (4) can be displaced upwards from the suction plane (4) individually or in groups in a controlled manner, in particular in such a way that each upper side gripper (4) is displaced upwards from the suction plane (4) during activation, either simultaneously or with a time delay. (Hold-down:).

5. Blank separating device according to claim 1, characterised in that with several hold-downs (15) either the undersides of the hold-downs (15) lie in a common horizontal hold-down plane (15) or the hold-downs are designed in such a way that they can adapt to an uneven, in particular sagging, top side of the stack.

6. Blank separating device according to claim 5, characterised in that the at least one hold-down device (15) is movably attached to a base frame (3A) of the supply station (3), and is, in particular in the height, in particular the vertical (10), movable as well as at least one of the two horizontal transverse directions (11, 12) being fixed movably thereto, and is, in particular in a hold-down frame (9) in one or both horizontal transverse directions (11, 12), adjustable in at least one, preferably both, transverse directions (11, 12), in particular are automatically adjustable in a controlled manner.

7. Blank separating device according to claim 6, characterised in that the at least one hold-down (15) is fixed to the tool body (2A) of the robot tool (2), in particular several hold-downs (15) and/or are arranged so as to be adjustable in their position relative to the tool base body (2A).

8. Blank separating device according to claim 6, characterised in that each hold-down (15) is associated with each top gripper (4), in particular, a hold-down (15) positioned radially further outwards with respect to the basic tool body (2A) is attached to each top gripper (4). (Supply aligner:).

9. Blank separating device according to claim 1, characterised in that the supply station (3) comprises a mechanical supply aligner (16) which holds and/or brings at least the uppermost punching sheet (SB), in particular the entire stack (13), into the desired position in the two horizontal directions (11, 12) by means of lateral stops (16a-d) which are adjustable, in particular adjustable in a controlled manner.

10. Blank separating device according to claim 9, characterised in that the mechanical supply aligner (16) is arranged either on the supply base frame (3A) or on the hold-down frame (9) or on the tool base body (2A).

11. Blank separating device according to claim 1, characterised in that the supply station (3) or the separating robot (1) comprises a non-contact position scanner (18) for the position of the uppermost punching sheet (SB) in the horizontal plane relative to the supply base frame, the separating robot is connected to the position scanner by data, in particular via the control system, so that it can still grip the blank (Z) to be gripped in the same gripping position of the basic tool body for the blank. (Blank magazine:).

12. Blank separating device according to claim 1, characterised in that a blank magazine (20), in particular one that is open upwards or to the side, is present in such a position that the separating robot (1) can deposit a blank (Z) held by it therein. (Test system:).

13. Blank separating device according to claim 1, characterised in that a non-contact inspection scanner (19) is present which checks the separated blank (Z) for quality features, in particular its shape and/or size and/or quality of its outer edges and/or quality of its printing and/or motif of its printing, in particular the test scanner (19) is either at a test station separate from the supply station (3) and the blank magazine (20), which is arranged in particular downstream of the supply station (3) and/or upstream of the blank magazine (20) or is arranged on the separating robot (1), in particular on the tool base body (2A).

14. Blank separating device according to claim 1, characterised in that the supply station comprises a lifting device (17) which guides the entire stack (13), in particular including the container (14) on which it rests, in height according to the decreasing height of the stack (13), so that the uppermost blank (Z) is always at approximately the same height.

15. Packaging machine (100) for inserting and packaging products (P) in a dimensionally stable outer packaging, in particular a cardboard box (K), with a cardboard box erector (60) for producing a cardboard box (K) from a flat blank (Z) of cardboard material, a plurality of transfer robots (110) along a transfer path for transferring products (P) into cardboard boxes (K), characterised by a blank separating device (50) for separating individual blanks (Z) from a stamping sheet (SB) with a plurality of blanks (Z) connected to one another via predetermined tearing points (M), in particular micro-connections (M).

16. Packaging machine according to claim 15, characterised in that the blank separating device (50) and/or the separating robot (1) is positioned in the packaging machine (100) in such a way that it can deposit a separated blank or a group of separated blanks (Z) held by it directly on the transport system (8) leading through the packaging machine (100), or optionally also in a blank magazine (20).

17. Packaging machine according to claim 15, characterised in that the packaging machine (100) comprises a transfer device (110), in particular a transfer robot (110), for transferring one or more individual blanks (Z) from the blank magazine to the carton erector (60) or a feed conveyor to the cardboard box erector (60), the transfer unit (110) or the infeed conveyor is designed as an alignment unit.

18. Method for producing separated blanks (Z) from a stack (13) of, in particular plate-shaped, stamping sheets (SB) with several blanks (Z) lying approximately in one plane and adjoining one another, connected to one another via predetermined tearing points (M), in particular micro-joints (M), in particular by means of a blank separating device (50), characterised in that one or more blanks (Z) from the uppermost or foremost stamping sheet (SB), in particular one lying on the stack, are automatically gripped and moved out of the sheet plane thereof while tearing off the target tear points (M) the remaining stamping sheet (SB) is automatically kept on the stack. (Pre-processing:).

19. Method according to claim 18, characterised in that before separating the blanks (Z), in particular before stacking the stamping sheets (SB), the inner waste produced by punching the sheet (B) and/or the outer waste outside the blanks (Z), in particular the punched grid, of the stamping sheet (SB) is removed from the stamping sheets (SB), and/or the blanks (Z) are printed ready for use on at least one side, in particular before being cut out of the stamping sheet (SB). (hold forcefully:).

20. Method according to claim 18, characterised in that when grasping and moving out of the sheet plane (SB) the blank (Z) is held non-positively on its upper side, in particular by means of suction force and/or the rest of the stamping sheet (SB) around the blank (Z) is thereby automatically held in the sheet plane (SB).

21. Method according to claim 18, characterised in that the separated blank (Z) is checked for quality features, in particular shape and/or size and/or quality of the peripheral edges and/or quality of the printing and/or motif of the printing, in particular before depositing in a blank magazine (20) or on the transport system (8) of the downstream machine, in particular a packaging machine (100). (Position correction:).

22. Method according to claim 18, characterised in that before gripping and lifting out the blank (Z) either the punching sheet (SB) is brought into a predetermined target position in the horizontal plane or the actual position of the blank (Z) or the stamping sheet (SB) is detected, especially in the horizontal plane, is compared with a target position and in the event of a deviation above a tolerance value, the deviation is communicated to the gripping tool for the blank (Z), in particular to a separating robot, or the actual position is changed to the target position.

23. Method according to claim 18, characterised in that the sheet, in particular the stamping sheet (SB), is selected in a standard size, in particular 3b.

24. Method of operating a packaging machine (100) including the separation of blanks (Z) according to claim 18 characterised in that the stack (13) of stamping sheets(S) is placed in the supply station (3) together with the delivery container, in particular a pallet (14) on which the stack (13) stands and/or in addition to the stack (13) of stamping sheets (SB), a supply of separated blanks (Z) is kept available to bridge standstill times of the blank separating device (50).

Description

EXAMPLES OF EMBODIMENTS

[0097] Embodiments according to the invention are described in more detail below by way of example. In the drawings:

[0098] FIGS. 1a, b: show a first design of the separating device in the top view in different functional positions,

[0099] FIGS. 2a, b: show the separating device of FIGS. 1a, b in the same functional positions in side view,

[0100] FIGS. 3a, b: show a second design of the separating device in the

[0101] top view in different functional positions,

[0102] FIGS. 4a, b: show a first design of the gripping tool in top view and side view,

[0103] FIGS. 5a, b: show a second design of the gripping tool in top and side view,

[0104] FIGS. 1a, 2a show a top view and a side view, the latter in the direction opposite to the direction of passage through the packaging machine 100, of the separating device 50 in its installed state in the packaging line 100 in a first operating position, and in FIGS. 1b, 2b in a second operating position.

[0105] The blank separating device 50 comprises, on the one hand, a supply station 3 and, on the other hand, a separating robot 1 with a gripping tool 2 on its robot arm for gripping and lifting a single blank Z from the uppermost stamping sheet SB of the stack 13 of stamping sheets, which is delivered on a Euro pallet 14 and is moved into and inserted into the supply station 3.

[0106] As FIGS. 1a, b show, the stack 13 is inserted into the interior of a module of the packaging machine 100 from the side, so that it stands with its longitudinal direction 11 transverse to the throughput direction 100 of the packaging machine 100 and still protrudes to the side from the base frame 100A of the module.

[0107] The robot 1 is here a serial robot, which is suspended with its robot base 1A in the upper area on the base frame 100A of the machine tool 100.

[0108] The machine tool 100 consists of several modules arranged one behind the other in the throughput direction 100, each consisting of the same base frame 100A, each consisting of four columns 100A1 arranged in a square, the upper ends of which are connected to each other by longitudinal cross members 100A3 and cross members 100A2 running in the throughput direction 100.

[0109] The robot 1 is suspended by its robot base 1A from one of the crossbars 100A2 of a base frame 100A or an additional crossbar, and its upper arm 1a is pivotable relative to the robot base 1A about an upright pivot axis.

[0110] At the free end area of the upper arm 1a, the lower arm 1b can also be swivelled about an upright axis, which carries a vertical crossbar 100c in its free end area, which can be moved in height to a limited extent in relation to the lower arm 1b and carries a gripping tool 2 at its lower end, shown here with two suction cups 4.

[0111] Due to the only limited height adjustment of the vertical traverse 1c and thus also of the suction cups 4, the height of the dismantling stack 13, in particular its uppermost punching sheet SB, must be tracked, which is why a lifting device 17 is provided.

[0112] This can engage under the top plate of the pallet 14 on both sides of the stack 13 including pallet 14 that has been moved into the supply station 3 with a respective lifting arm 17.1, 17.2, which forks downwards and has short tines 17a projecting towards the other lifting arm at the lower end, in order to lift the entire pallet 14. For this purpose, the upper part of each of the lifting arms 17.1, 17.2 or both together is guided on a lifting guide 17b and can be raised by motor.

[0113] In order to prevent the rest of the top sheet SB from being lifted when one of the blanks Z is gripped and lifted by the separating robot 1 and its gripping tool 2, which would result in an uncontrolled tearing off of the micro-joints M, the adjacent blanks Z on the top side of the stack 13 are held down by means of a holding-down device 15.

[0114] In this case, the hold-down device 15 consists of a hold-down frame 9 which is rectangular in plan view and whose inner free space is in particular larger than the largest stack 13 to be accommodated, usually larger than a Euro pallet 14.

[0115] Inside the frame 9, two hold-down bars 16.12 are guided, which are variable in their distance and run in the transverse direction 12 of the stack 13, and can be adjusted, in particular, by motor drive or manually.

[0116] Between these two hold-down bars 16.12, a length-adjusting hold-down bar 16.11 running in the other horizontal transverse direction 11 is attached, which runs in the longitudinal direction 11 of the stack 13 and is adjustable in its transverse direction 12, i.e. can be moved along the hold-down bar 16.12, in particular can be moved in an automatically controlled manner.

[0117] Before lifting the blank Z to be separated, these hold-down bars are positioned as close as possible to the outside of the parting lines L between the adjacent blanks Z when viewed from above, and likewise the suction cups 4 of the gripping tool 2 are positioned as close as possible to and inside the blank Z at the parting lines L.

[0118] When the blank to be separated is lifted, the hold-downs 15 are and remain lowered until they are in contact with the uppermost punching sheet SB, which is why the hold-down, in this case in particular the hold-down frame 9, is adjustable in height in a controlled manner, in particular here fixed either to the lifting arms 17.1, 17.2 or directly to its own lifting guide fixed to the base frame 100A of the machine tool.

[0119] In the present case, there is sufficient space between the supply station 3, i.e. the set stack 13, and the opposite longitudinal side of the base frame 100A to arrange a discharge conveyor 8 running in the throughput direction 100, on which the separating robot 1 deposits the separated blank Z in each case, as is only indicated in FIG. 1a and takes place in FIG. 2a.

[0120] FIGS. 1b, 2b, on the other hand, show how a blank Z already lying on the discharge conveyor 8 is removed from the latter, while the robot 1 with its gripping tool 2 just grips one of the last three blanks Z forming a row, which, viewed from above, are already outside the base frame 100A of this module of the packaging machine 100, the hold-down device 15 with its hold-down bar 16.11, 16.12 is set in such a way that the blank Z adjoining in the transverse direction 12 of the stack 13 is held down by the hold-down bar 16.11, while the two hold-down bars 16.12 running in the transverse direction 12 are already out of function, since there is no longer a stamping sheet there on which they can rest.

[0121] Also when blanks Z are picked up at other positions of the punching sheet, one of these hold-down bars 16.2 is usually out of function insofar as it no longer rests on the punching sheet but only serves to guide the hold-down bar 16.11 running in the other direction.

[0122] FIGS. 1a, b also show, viewed from above, in this case angular stack aligners 16a, which are preferably also attached to the hold-down frame 9, are in any case part of the supply station 3 and extend downwards from aboveas shown by way of example in FIG. 2ato such an extent that at least the uppermost or some of the uppermost stamping sheets SB are held in position between the stack aligners 16a, which can be positioned exactly, which can be adjusted relative to the hold-down frame 9, preferably in the longitudinal direction 11 as well as in the transverse direction 12 of the inserted stack, either manually or automatically controlled, so that the robot 1 knows the exact actual position of the uppermost stamping sheet SB.

[0123] FIGS. 1a, b also showomitted in FIGS. 2a, b for reasons of claritya blank magazine 20 in which the separating robot 1 can deposit a separated blank Z instead of depositing it directly on the discharge conveyor 8 and feeding it into the packaging process.

[0124] If the function of the blank separating device 50 is interrupted, for example because a new full pallet 14 has to be placed in the supply station 3, the separating robot 1 can bridge this time by removing blanks from the blank magazine 20 and placing them on the discharge conveyor, thus continuing to supply the packaging machine with separated blanks.

[0125] Whereas in FIGS. 1a, b the blanks Z were essentially rectangular and arranged next to each other in rows and columns, the views of FIGS. 3a, b show blanks Z that are strongly cross-shaped and partially overlap each other both in the longitudinal direction 11 and in the transverse direction 12 of the stamping sheet, so that this causes multiple angled separating lines L between the individual blanks. Accordingly, two hold-down bars crossing each other at right angles can never run along the entire parting line, but only over partial areas of the parting lines.

[0126] If this is not sufficient, instead of the straight hold-down bars e.g. 16.11, hold-down bars 16.11, 16.12 adapted to the specific shape of the blank and also angled or having an angled edge can be used.

[0127] FIGS. 3a, b further differ from FIGS. 1a, b in that the separating robot 1 does not simply place the separated blank Z on the discharge conveyor 8 for transport away, but there is an erector 60 with the erecting die 61 above the discharge conveyor 8, and the robot 1 places the blank Z at least in the exact position on the erector 60, or even presses it through the die 61 until it is standing underneath on the discharge conveyor 8 in the erected state.

[0128] However, before pressing through, it must be ensured that the gripping tool 2 does not project laterally beyond the bottom section of the blank Z at any point when viewed from above, or a corresponding pressing tool must be extendable from the underside of the base body 2a of the gripping tool 2 as a pressing plunger.

[0129] The problems with adapting hold-downs along, for example, the hold-down frame 9, which surrounds the entire stack 13 when viewed from above, can be avoided or minimised if the hold-downs are arranged directly on the base body 2A of the gripper tool 2 and are adjustable there, as shown in the two designs of FIGS. 4a, b and 5a, b:

[0130] In the design according to FIGS. 4a, b, spokes 21 project radially from the central part 2Az of the base body 2A, in this case 8 spokes distributed evenly over the circumference, which are connected at their outer ends by a circumferential ring for stabilisation.

[0131] Along the spokes 21, i.e. in the radial direction, both a suction cup 4 and a hold-down 5 are attached and adjustable, their lower contact surfaces being approximately at the same height.

[0132] In the right half of FIG. 4a, including the spokes 21 extending exactly upwards and downwards in FIG. 4a, the respective suction cup 4 is connected to the respective hold-down 5 located radially outside it to form a fixed unit, i.e. at a fixed radial distance.

[0133] This functional unit is then set for the respective blank Z in such a way that the suction cup 4 is located just inside the blank Zas seen from aboveand the hold-down 5 just outside.

[0134] Since, depending on the course of the circumferential line of the blank Z to be separated, this does not always result in the optimally small distance to the circumference, the suction cups 4 and hold-down devices 5 lying outside of them can alternatively be moved independently of each other along the three spokes 21 pointing to the left, whichas can be seen in particular from the spoke 21 pointing exactly to the leftenables very close positioning of the suction cup 4 inside and of the hold-down device 5 outside of the circumferential line of the blank Z.

[0135] As a rule, these settings are only carried out manually once before the start of processing a batch of blanks Z.

[0136] In contrast, the design of FIGS. 5a, b shows a design in which the base body 2A of the gripping tool 2 consists of a perforated plate as a suction cup support plate 6, whichlike the spoke wheel in FIGS. 4a, bis larger than a blank Z to be grip.

[0137] Both the hold-down device 5 and the suction pad 4 are designed in such a way that they can be inserted into one of these holes 22, in particular from below, and in particular lock into place therein.

[0138] During suction, the suction cups move upwards and/or the hold-downs move downwards, causing the micro-joints to be torn off.

[0139] In this way, the suction cups 4 on the one hand and the hold-downs 5 on the other hand can be positioned just inside or just outside the circumferential line L of the blank Z to be handled, and then the suction cups 4 can be connected to the central part 2Az of the base body 2a for vacuum supply only by means ofpreferably plug-inhoses for vacuum supply.

REFERENCE LIST

[0140] 1 Separating robot [0141] 1A Robot base [0142] 1Az Base body central area [0143] 1a Upper arm [0144] 1b Lower arm [0145] 1c Vertical brace [0146] 2 Gripping tool [0147] 2A Base body [0148] 3 Supply station [0149] 3A Base frame [0150] 4 Top grippers, suction cups [0151] 4 Suction level [0152] 5 Suction arm [0153] 6 Suction cup support plate [0154] 7 Fastening device, through-opening [0155] 8 Conveyor [0156] 9 Hold-down frame [0157] 10 Vertical [0158] 11 Longitudinal direction of stamping sheet [0159] 12 Transverse direction punching sheet [0160] 13 Stack [0161] 14 Pallet [0162] 15 Hold-down [0163] 15 Hold-down plane [0164] Hold-down bar [0165] 15.11, 15.12 Supply aligner [0166] 16 Stop [0167] 16a Lifting device [0168] 18 Position scanner [0169] 19 Test scanner [0170] 20 Blank magazine [0171] 21 Spoke [0172] 22 Passage opening [0173] 23 Hose [0174] 50 Blank separating device [0175] 50* Control [0176] 60 Cardboard box erector [0177] 61 Matrix [0178] 100 Packaging machine [0179] 100 Direction of flow, longitudinal [0180] 100A Base frame [0181] 100A1 Column [0182] 100A2 Crossbar [0183] 100A3 Longitudinal crossbar [0184] 112 Running direction 102 [0185] K Cardboard [0186] L Dividing line [0187] M Micro-connection, nominal tear point [0188] P Product [0189] SB stamping sheet [0190] SB stamping sheet plane [0191] Z Blank