Container sizing method and system

Abstract

A carton sizing system that has a frame, a controller, one or more cutters movably mounted to the frame and operatively connected to the controller, one or more markers movably mounted to the frame and operatively connected to the controller. The carton sizing system also has a measuring means that is operatively connected to the controller 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 is configured to position the one or more cutters 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 based on the determined footprint and height and to score or crease vertical walls of the carton between the vertical edges to at least partially define foldable panels.

Claims

1. A method of closing containers comprising: receiving a first container and one or more objects within the first container; determining a first height, a first width, and a first length of the container; determining a height of one or more objects within the first container; cutting vertical edges of the container based on the determined height of one or more objects within the first container; marking sidewalls of the container based on the determined height of one or more objects within the first container, and closing the sidewalls of the container to enclose the one or more objects within the container.

2. The method of claim 1, further comprising: receiving a second container having a second height, a second width, and a second length wherein the second width is different from the first width, and wherein the second length is different from the first length; determining the second height, the second width, and the second length of the second container and one or more objects within the second container; cutting vertical edges of the second container based on a determined height of one or more objects within the second container; marking sidewalls of the second container based on the determined height of one or more objects within the second container; and closing the sidewalls of the second container to enclose the one or more objects within the second container.

3. The method of claim 2, wherein and the second height of the second container is different from the first height of the first container.

4. The method of claim 2, further comprising receiving a third container having a third width different from the first and second widths and a third length different from the first and second length.

5. The method of claim 4, wherein the first container, the second container, and the third container are sequentially received, scanned, cut, marked, and closed having no intervening container between the first container and the second container, and no intervening container between the second container and the third container.

6. The method of claim 4, further comprising maintaining constant tooling for scanning, cutting, marking, and closing each of the containers.

7. A container forming system comprising: a camera system for determining a height, a width, a length of a container and one or more objects within the container; a cutter configured to sequentially cut vertical edges of the container based on a determined height of one or more objects within the container; a marker configure to crease sidewalls of the container based on the determined height of one or more objects within the container; a closing station for enclosing the one or more objects within the container; and a controller configured to move the cutter and the marker based on a determined floorplan and height of each container.

8. A container sizing system for sizing open top cartons having varied widths, lengths, and heights, 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, lengths, and heights; 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, lengths, and height; and a measurement system operatively connected to the controller and configured to determine, in use, a width, a length, and a desired height of an open top carton and to determine a height of one or more objects to be 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 to be contained within the open top carton cause the robotic arm(s) to move the one or more marker element pairs in the vertical direction, and first horizontal direction and the second horizontal direction based on the one or more objects to be 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.

9. The system of claim 8, wherein the one or more markers are moveably mounted to the frame by a vertical support configured to move in the vertical direction, the first horizontal direction, and the second horizontal direction along guide rails aligned in the first horizontal direction and the second horizontal direction.

10. The system of claim 9, wherein the one or more markers are rotatably coupled to the vertical support by a first joint and configured to move rotatable in a yaw plane.

11. The system of claim 10, wherein the one or more markers are each respectively coupled to the first joint by a marker arm having a second joint and a third joint.

12. The system of claim 11, wherein the second joint and the third joint are each rotatably moveable in a pitch plane.

13. The system of claim 12, wherein the one or more markers are each rotatably coupled to the respective third joint and moveable in the yaw plane.

14. The system of claim 8, wherein the one or more cutters are moveably mounted to the frame by a vertical support configured to move in the vertical direction, the first horizontal direction, and the second horizontal direction along guide rails aligned in the first horizontal direction and the second horizontal direction.

15. The system of claim 14, wherein the one or more cutters are rotatably coupled to the vertical support by a first joint and configured to move rotatable in the yaw plane.

16. The system of claim 15, wherein the one or more cutters are each respectively coupled to the first joint by a cutter arm having a second joint and a third joint.

17. The system of claim 16, wherein the second joint and the third joint are each rotatably moveable in the pitch plane.

18. The system of claim 17, wherein the one or more cutters are each rotatably coupled to the respective third joint in the yaw plane.

19. A method of sizing and forming a container comprising: scanning by a vision system a width and a length of a first container; scanning by the vision system contents and arrangement of the contents of the container within the first container; determining a start position for a cutter based on scan results of the first container; cutting at least a portion of the wall of the first container in a first cutting path; determining a starting creasing position for a creaser to crease walls of the first container; and creasing a first portion of a wall of the first container.

20. The method of claim 19, further comprising: scanning by the vision system a width and a length of a second container; scanning by the vision system contents and arrangement of the contents of the container within the second container; determining a start position for the cutter based on scan results of the second container; cutting at least a portion of the wall of the first container in a second cutting path, wherein the first path is different than the second path; determining a starting creasing position for a creaser to crease walls of the second container; and creasing a first portion of a wall of the second container.

21. The method of claim 20, wherein the second container includes a different floor plan from the first container.

22. The method of claim 20, wherein the creaser is moved along a wall of the first container to a second portion of the wall of the first container and creasing the second portion of the wall of the first container.

23. The method of claim 22, wherein creasing the first portion of the first wall includes squeezing a roller and an anvil member from a first position to a second position to form a crease and moving the roller and the anvil member in the second position along the wall to the second portion of the first wall to crease the second portion of the second wall.

24. The method of claim 20, wherein the creaser is shorter than a wall of the container.

25. The method of claim 20, wherein scanning includes capturing a first image by a first camera and a second image by a second camera.

26. The method of claim 25, wherein the first image is captured from above the container.

27. The method of claim 25, wherein the second image is captured from a side of the container.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(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.

DETAILED DESCRIPTION

(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 23 a, 23 b 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 23 a 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.

(15) 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.

(16) 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.

(17) 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.

(18) 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.

(19) 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.

(20) 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 4 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.

(21) 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).

(22) 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.

(23) The vertical support 202 and housing 250 are mounted on a first pair of guide rails 210 a, 210 b 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.

(24) The positioning system 200 also has a second pair of guide rails 220 a, 220 b, 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.

(25) The positioning system 200 has a further, third, pair of guide rails 230 a, 230 b, along which the position of the vertical support 202, housing 250 and second pair of guide rails 220 a, 220 b 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).

(26) 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.

(27) 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 622 a 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.

(28) 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.

(29) 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.

(30) 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.

(31) 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.