A System Having a Robotic Functionality for a Division Process of a Pressed and Cased Tobacco Bale Inside its Original Case into 2 or More Pieces

Abstract

A system for a division and separation process of a full-size tobacco bale through its horizontal direction without removing it from its original case, positioning of the upper piece into another empty case and completing all sub-processes with compact solutions. The mechanical features of process used during the division of tobacco bale inside case are the folding of case side flaps, ensuring of holding them steadily during entire process, measuring the incoming case weight, creating free space in between case side walls and tobacco bale, travels of dividing arms in to the free space, rotation and pulling up the section of the tobacco bale outside and releasing of this upper section into upcoming empty case.

Claims

1. A full-size tobacco bale dividing system comprising multiple conveyors, which allows an upper half of a tobacco bale inside a case to be divided and the upper half to be taken apart, and then placed into a new empty case as finally being divided into two cases wherein the system comprises: dedicated dividing arms that can rotate over its shaft where they are fully positioned over a main carriage system table with the parallel direction of the case long sides and leading to the separation/division of full-size tobacco bale into two or more pieces horizontally; a main carrier system that drives the main carrier system table upwards and downwards with the cutting arms those are attached on in vertical direction; dividing arm servo motors that drive and rotate the dividing arms, which are positioned opposite to each other as parallel to the long side of the case from the defined 0 position until its perpendicular 90 degree position from both sides case with gradual steps, and wherein the system contains at least one tobacco bale dividing robot.

2. A full-size tobacco bale dividing & separating system according to claim 1, comprising case long side opening arms that open the long side of the case from both sides and allow the dividing arms to travel/enter in between the case long side walls and the full-size tobacco bale.

3. A full-size tobacco bale dividing & separating system according to claim 1, comprising case long side holding parts are placed onto the case long sides by the operator in advance so that long side opening arms shall hold steadily the case long sides afterwards.

4. A full-size tobacco bale dividing & separating system according to claim 1, wherein the case short side holding parts are placed on the case short sides by the operator in advance so that the case short sides remain steady and not bended during entire stretching process of case long side opening arms.

5. (canceled)

6. (canceled)

7. (canceled)

8. A full-size tobacco bale dividing & separating system according to claim 1, comprising a third conveyor where the preparations are proceeded by the operator for a proper division process inside the bale dividing robot is realized later on, and a vertical movement element located at the corners of the third conveyor, which enables the up-and-down movement of the case over the third conveyor.

9. (canceled)

10. (canceled)

11. A full-size tobacco bale dividing & separating system according to claim 10, comprising a fourth conveyor located at the bottom position of the tobacco bale dividing robot and a weight sensing measurement unit in the fourth conveyor that measures the weight of the case containing the half-size tobacco bale.

12. A full-size tobacco bale dividing & separating system according to claim 1, comprising a counter pressure application plate that ensures steady position with gentle pressure application on to the top surface of the full-sized tobacco bale during the bale division process.

13. A full-size tobacco bale dividing & separating system according to claim 1, comprising dividing arms with the proper sizes for not getting in contact to each other during rotation of dividing arms by having a relatively less size of the half dimension of case short size.

14. A full-size tobacco bale dividing & separating system according to claim 1, comprising four dividing arms located at each long sides of the case.

15. A full-size tobacco bale dividing & separating system according to claim 14, comprising relatively longer cutting arms in the centre section so that the middle section of divided tobacco bale is hold properly and not deformed & falls down.

16. (canceled)

17. A method for dividing & separating of a full-size tobacco bale in a case by removing the upper half of the bale across its width horizontally, placing it into an empty case, and separating a full-size tobacco bale into two cases while being repacked in a system, the method comprising: positioning of a case containing a full-size tobacco bale under a tobacco bale dividing robot; dividing arms of the tobacco bale dividing robot entering through the side walls of the case and the tobacco bale travelling downward in vertical direction up to half height of the full-size tobacco bale; rotation of the dividing arms from their 0 position parallel to the long side of the case to its 90 position perpendicular to the long side of the case gradually; division of the full-size tobacco bale via rotation of the dividing arms horizontally; and vertical movement of the dividing arms already rotated 90 angle leading the separation of full-size tobacco bale into an upper tobacco bale and a lower tobacco bale.

18. The method for dividing and separating of a full-size tobacco bale of claim 17 wherein the case long sides are extracted via case opening arms in order to create free space in between tobacco bale and case.

19. The method for dividing and separating of a full-size tobacco bale of claim 18, wherein case long-side holding parts are positioned by the operator in order to be hold by case long side opening system.

20. The method for dividing and separating of a full-size tobacco bale of claim 18, wherein case short-side holding parts are positioned by the operator in order to prevent bending of the case short sides.

21. The method for dividing and separating of a full-size tobacco bale of claim 17, wherein the process of dividing arms rotation from 0 degree to 90 is performed in multiple steps through the full-sized tobacco bale horizontally.

22. The method for dividing and separating of a full-size tobacco bale of claim 21, wherein the rotation of the dividing arms is in between 0 to 30 in each step.

23. The method for dividing and separating of a full-size tobacco bale of claim 21, comprising specific step base movements of the dividing arms with the sequential movement of dividing arms upwards in X direction and downwards in Y direction after 1 step of rotation is completed in order to facilitate dividing process and easy separation of the full-sized tobacco bale.

24. The method for dividing and separating of a full-size tobacco bale of claim 17, comprising the transfer of case having inside the lower part of tobacco bale to the fifth conveyor, removing of all side flaps holding pieces, case side flaps folding and closing, and strips application over the case are realized by the operator.

25. The method for dividing and separating of a full-size tobacco bale of claim 17, comprising the releasing of the upper half bale of tobacco stays on dividing arms into the new case travelled over forth conveyor.

26. The method for dividing and separating of a full-size tobacco bale of claim 17, comprising application of gentle pressure over full size tobacco bale via counter pressure plate during entire division & separation sub-processes.

Description

BRIEF EXPLANATION OF FIGURES

[0018] The invention will be described with reference to the accompanying drawings, so that the features of the invention will be clearly explained. However, the purpose is not to limit the invention to these particular arrangements. On the contrary, it is intended to encompass all alternatives, modifications, and equivalents that may be included within the scope of the claims defining the invention. The details shown are for the purpose of illustrating preferred embodiments of the invention and should be understood as being presented for the purpose of providing the most useful and readily understandable definition of the methods of shaping the invention, as well as the rules and conceptual features of the invention. In these drawings;

[0019] FIG. 1; A perspective view of the entire system subject of the invention.

[0020] FIG. 2; Perspective & exploded views of the tobacco bale division robotic unit referred in this invention.

[0021] FIG. 3; The visuals of how the manual preparation steps are applied to the tobacco case on conveyor number three.

[0022] FIG. 4; Additional visuals of how the automated processes are applied to the tobacco case on conveyor number three.

[0023] FIG. 5; The visuals where the tobacco bale inside original case with the top lids are open and is positioned underneath the dividing robot (at number 4 on the conveyor).

[0024] FIG. 6; The visuals that show the long sides of the case being pulled outwards to allow the dividing arms of the robot to enter in between case & tobacco bale.

[0025] FIG. 7; The visual shows that the arm of the dividing robot moves downwards in that free space up to the level determined by the automation system.

[0026] FIG. 8; The visual shows that how the counter balancing, plate goes down in order to hold tobacco bale in new case in proper shape.

[0027] FIG. 9A, 9B, 9C, 9D, 9E; The consecutive visuals show the main dividing robot and how the robot arms operate with short distances & intervals with the sequence of limited rotation of the arms and then all arms movement up-down that fully facilitates the separation of the pressed tobacco leaf from each other.

[0028] FIG. 10; The visual shows that the tobacco bale is divided into two pieces after the full 90 degree turn of the cutting arm is completed.

[0029] FIG. 11; The visual is of the divided upper tobacco bale, held in between the dividing arms that rotated a full 90 turn and how system and this section is moved up together with the main carriage unit.

[0030] FIG. 12; The visual shows how the remaining half bale inside original case is measured in weight to check division accuracy & process control before next step.

[0031] FIG. 13; The visual shows how weight controlled half tobacco bale is taken out of robot area, where side flaps closing and strapping activities are handled manually in order to ensure process completion & case rigidity purpose.

[0032] FIG. 14; The visual shows the position where the next/empty case top lids are folded and transferred underneath dividing robot arms.

[0033] FIG. 15; The visual shows that how the divided upper tobacco bale piece is entered into empty box.

[0034] FIG. 16; The visual shows the opening of the dividing/rotating arms, after properly positioned inside the empty box.

[0035] FIG. 17; The visual shows how the divided section of tobacco bale is released into empty case while robot is moving upwards; and counter balance plate moves downwards that, ensures half tobacco bale is properly placed inside.

[0036] FIG. 18; The visual shows how complete robotic system is moved, upwards once properly releases half bale into the case.

[0037] FIG. 19; The visual shows how the manual operation is handled in the known technique.

[0038] FIG. 20; The visual shows how the vertical dividing process is realised in the known technique.

REFERENCE NUMBERS

[0039] 1. First Conveyor [0040] 2. Second Conveyor [0041] 3. Third Conveyor [0042] 3.1. Case long side flaps steady folding & holding metal pieces [0043] 3.2. Case short side flaps steady folding metal pieces [0044] 3.21 Slope [0045] 3.3. Case front stopper as movable item on the conveyor [0046] 3.4. Case lateral guiding unit as movable item on the third conveyor [0047] 3.5. Weight measurement element on the third conveyor [0048] 3.6. Case Up-down driving unit on the third conveyor [0049] 4. Forth conveyor [0050] 4.1. Weight measurement element on the fourth conveyor [0051] 5. Tobacco bale dividing robot [0052] 5.1. Case long side flaps opening unit [0053] 5.2. Carriage system main process plate [0054] 5.3. Main carriage system [0055] 5.4. Dividing arms [0056] 5.5. Dividing arms driving servo motor [0057] 5.6. Counter pressing plate [0058] 5.7. Purge air control valve [0059] 5.8. Weight measurement data display unit [0060] 6. Fifth conveyor [0061] 6.1. Strip channels [0062] 7. Sixth conveyor [0063] 8. Seventh conveyor [0064] A. Case [0065] B. Full size tobacco bale [0066] C. Tobacco bale upper section [0067] D. Tobacco bale lower section [0068] E. Strap [0069] X, Y movement directions

DETAILED EXPLANATION OF THE INVENTION

[0070] The invention subject of tobacco bale dividing system is described in this detailed explanation only for the purpose of better understanding the subject, and with no restrictive effect, using examples. The specification describes a system that involves horizontal dividing & taking apart the upper half of a full-size tobacco bale (B) inside a case (A), transferring it into another empty case (A), and as conclusion, dividing 1 full case into two cases with half amount product (A) to be packed, thereby allowing a tobacco bale (B) to be split between two cases (A).

[0071] In FIG. 1, the general view of the tobacco bale dividing system is given. Accordingly, the system consists of seven conveyors and a tobacco bale dividing robot (5) positioned on the conveyor located in the centre.

[0072] In this system, the first conveyor (1) and the second conveyor (2) are conveyors with 2 cases (A) on top, and only the first case where a full tobacco bale (B) is fed into system.

[0073] The third conveyor (3) is the section where the preparation processes of the case (A) are carried out prior to transfer to the tobacco bale dividing robot (5). On the third conveyor (3), the strips (E) are removed, covers of the case (A) are opened, some extra metal flap guiding pieces are placed on the long and short flaps of the case (A) and finally full case weight is measured.

[0074] The Fourth conveyor (4) is the section where the tobacco bale (B) inside the case (A) is horizontally divided by the tobacco bale dividing robot (5) as the upper tobacco bale (C) and the lower tobacco bale (D) pieces.

[0075] The sixth conveyor (6) serves as an exit conveyor for the case (A) where the lower tobacco bale (D) of the tobacco bale (B) with the upper half removed is transferred. In this section, the case side flaps steady folding & holding parts (3.1 & 3.2) are removed from the case (A), its flaps are closed, and its new strips (E) are stretched for re-packaging.

[0076] The Sixth (7) and Seventh (8) conveyors are the storage conveyors at the system output.

[0077] In FIG. 2, the details of the tobacco bale dividing robot (5), which is the main section that performs the task in the invention, are given. The tobacco bale dividing robot (5) divides the full-sized tobacco bale (B) inside the box (A) into two or more parts horizontally, obtaining the upper tobacco bale (C) and the lower tobacco bale (D). Although the current desired condition in the industry is to divide the tobacco bale (B) into two equal parts, the tobacco bale dividing robot (5) has the ability to divide the full-sized tobacco bale (B) into more than two pieces. At the same time, the tobacco bale dividing robot (5) can also divide the full-sized tobacco bale (B) into unequal pieces. The operating parameters shall be selected on preference and requirements.

[0078] In the tobacco bale dividing robot, which is subject of the invention (5), there are case long flaps opening arms (5.1) that open the both sides of the case (A) in which the full-size tobacco bale (B) is located. These arms (5.1) pass through the claws in the case long side flaps holding parts (3.1) on the case (A) and provide the free space in between long sides of the case (A) and the cutting arms (5.4) that divide the upper half of the full-size tobacco bale (B) inside the box (A) can enter into the box (A).

[0079] In the tobacco bale dividing robot (5), the dividing arms (5.4) are placed on a main carrier system table (5.2) where they can rotate around their axes. The dividing arms (5.4) can rotate gradually from its zero/reference position, where it is steadily hold as parallel to the long side of the case (A), up to 90 where it is perpendicular to the case long sides. The rotation movement of the dividing arms (5.4) is driven by the dividing arm servo motors (5.5), where they are located on the main carrier system table (5.2). The main carrier system table (5.2) moves vertically on the main carrier system (5.3). In the tobacco bale dividing robot (5), there is a servo motorized pressing group (5.6) to apply counter pressure to the divided upper half tobacco bale vertically. In addition, in the tobacco bale cutting robot (5), there is an air control valve (5.7) blowing air onto the pressing plate (5.6) to prevent tobacco particles from being spread around/outside box while being divided into two.

[0080] FIGS. 3 and 4 show the details of the manual and automatic preparation operations performed on the third conveyor (3) in the system. First, an operator removes the strips (E) of the case (A) and opens/folds all case flaps on this third conveyor (3). Then, the same operator places case flaps steady holding parts (3.1 & 3.2) on the long and short flaps of the case (A). The long side holding parts (3.1) is to be considered as having two functions: first, to ensure that the long side flaps of the case remain fully open & steady, and the second, to be associated later on with the tobacco bale cutting robot (5) and the case long side opening arms (5.1) on the fourth conveyor (4). The case long side opening arms (5.1) extends the long sides of the case (A) by applying a pulling force, creating enough space for the cutting arms (5.4) to enter in between. The box short side holding parts (3.2) is used to prevent the short sides of the box from flexing or bending during the expansion of the long side of the case (A). Additionally, the box short side fixation attachment (3.2) has a sloping surface (3.2.1) to facilitate the placement of the full-size tobacco bale (B) inside the empty box (A). (As shown in FIG. 6)

[0081] In the third conveyor (3), there is a weight measurement system (3.5) that measures the weight of the case (A). There are 4 (four) pieces of this measurement system located on all around third conveyor. In the corners of the third conveyor (3), there are also case lifting items (as up-down movement) (3.6) that can move the case (A) in the vertical direction.

[0082] In addition, there is a front stopper unit (3.3) as moveable that stops the case (A) from the front/short side and the case lateral guiding unit (3.4) that directs and positions the case (A) from its long sides right after transferred onto the third conveyor (3).

[0083] In FIG. 5, the case (A) has been transferred from the third conveyor (3) to the fourth conveyor (4) and positioned under the tobacco bale dividing robot (5).

[0084] In FIGS. 6 and 7, case long side opening arm (5.1) is extracting the long sides of the case (A) by applying pulling power to the case long side holding parts (3.1). As aiming to, when the main conveying system (5.2) moves downward in the vertical direction, the cutting arms (5.4) can enter through the gap in between the case (A) side walls and the full-size tobacco bale (B).

[0085] Initially, the dividing arms (5.4) move forward until half the size of the full-size tobacco bale (B), and then a low-intensity pressure is applied to the upper surface of the full-size tobacco bale (B) with the counter pressure plate (5.6), as seen in FIG. 8. The dividing (5.4) arms are 4 (four) pieces as set. This quantity shall be less or more but for this separation method, based on test results, represented as the most effective way for proper division.

[0086] In FIG. 7, the dividing arms (5.4) are completely closed. When the dividing arm motor (5.5) rotates these cutting arms (5.4) on the main support system table (5.2), the cutting arms (5.4) move into the full-size tobacco bale (B).

[0087] The most critical stage of the technique as the process of dividing the full-sized tobacco bale (B) is the gradual rotation movement of the dividing arms (5.4). To better understand this gradual movement; as example, when the cutting arms (5.4) rotates into the full-sized tobacco bale (B) by 10, they stop and right after that, all system as the main carriage unit (5.3) moves upwards and downwards for approximately 10 cm in order to partially separate and weaken the stickly tobacco pieces of the full-sized tobacco bale (B). Then, the cutting arms (5.4) rotate again by another 10 and this cycle continues until the rotation of the cutting arms (5.4) reaches until 90 angle. As a result of this process, the system divides the full-sized tobacco bale (B) into the upper tobacco bale (C) and the lower tobacco bale (D) properly & reliably.

[0088] The detailed process explanation of the previous paragraph is shown in detail in FIGS. 9A, 9B, 9C, 9D, and 9E. Firstly, the dividing arms (5.4) rotate into the full-size tobacco bale (B) (FIG. 9A). This rotation is greater than 0 but less than 30 (preferably 10). When the dividing arms (5.4) rotation is completed, the main carrier system (5.3) moves in the X direction (FIG. 9B) and then moves in the Y direction (FIG. 9C). The main carrier system's (5.3) up and down movement repeats with each movement right after each dividing arms (5.4) rotation inside the full-size tobacco bale (B) at an angle greater than 0 but less than 30 (FIGS. 9D, 9E). At the end of these steps, the cutting arms (5.4) reaches to 90 inside the full-size tobacco bale (B) as shown in FIG. 10, and the tobacco bale (B) is separated into the upper tobacco bale (C) and lower tobacco bale (D) as shown in FIG. 11.

[0089] The process of dividing the tobacco bale (B) into two halves is carried out through the gradual rotational movement of the cutting arms (5.4) and the repeated up and down separating movements of the main carrier system (5.3). While these processes continue, the counter pressure plate (5.6) continues to remain over the upper section and applies gentle pressure. This way, the upper tobacco bale (C) between the dividing arms (5.4) and the counter pressure plate (5.6) can be separated from the lower tobacco bale (D) without any deformation, de-shaping or loss firmness. Thanks to this gradual separation process of the full-size tobacco bale (B), the dividing/separating process operates more stably and the equipment used can have much longer lifetimes as they are mechanically stressed less.

[0090] In the invention, the most important aspect is the movement of the dividing arms (5.4) that enables the separation of the full-size tobacco bale (B). The cutting arms (5.4) are associated with the shafts in such a way that they can rotate on the vertical axis of the main carrier system table (5.2). Thus, the dividing arms (5.4) proceeds step by step by rotating from 0 to 90 inside the full-size tobacco bale (B). The length of the cutting arms (5.4) is designed to be shorter than half the width of the full-size tobacco bale (B). There are two reasons for this. The first is to prevent the cutting arms (5.4) to hitting to each other during their rotation, and the second is to reduce the moment force required for rotation. Additionally, the length of the cutting arms (5.4) in the middle section is slightly bigger than the other cutting arms (5.4). This prevents the collapse of the middle section of the full-size tobacco bale (B). This situation can be observed in FIG. 10.

[0091] In FIG. 11, the lower tobacco bale (D) remaining in the case (A) is seen, while the upper tobacco part (C) moved up by the tobacco bale dividing robot (5) is shown.

[0092] In FIG. 12, in order to verify that the two half tobacco bales (C, D) after dividing process are divided equally, there is additionally feature over fourth conveyor (4) a weight measurement unit (4.1) that measures the lower tobacco bale (D) in the case (A), and the weight result is displayed on the weight indicator (5.8) and this data is electronically checked to confirm that the process is completed within tolerances by controlling the input-output weights.

[0093] In FIG. 13, the tobacco bale dividing robot (5) process is completed as it is holding the upper tobacco bale (C) and the bottom tobacco bale (D) inside the box (A) is transferred to the fifth conveyor (6). After this step, the long side holding devices (3.1) and short side holding parts (3.2) of the box (A) are removed by the operator, the flaps of the case are closed, and after tightening of the strips (E), the case is transferred to the sixth conveyor (7) and seventh conveyor (8) which are defined in the process as system unloading conveyors. The strip channels (6.1) on the fifth conveyor (6) allow the operator to easily tie up the strips (E) of the box (A).

[0094] In FIG. 14, it is shown that while the operations of the case (A) containing the bottom tobacco bale (D) are completed, another empty case (A) has arrived onto the fourth conveyor (4). The flaps of this empty case (A) are opened, and the long & short sides flaps holding items (3.2 & 3.2) are already positioned by the operator. As in the previous steps, the case long-side opening system (5.1) stretches the long sides of the empty cases (A) by applying pulling force from the case long side holding items (3.1), and the tobacco bale dividing robot (5) travels downwards and places the upper tobacco bale (C) into the empty box (A).

[0095] In FIGS. 15 and 16, it is shown that how the upper tobacco bale (C) advances into the empty box (A) and how the slope (3.21) in the box short side holding parts (3.2) allows this upper tobacco bale (C) slides easily into the box (A) without any shape deformation.

[0096] In FIGS. 17 and 18, after the upper tobacco bale (C) is placed into the case (A), the dividing arms (5.4) rotate to the 0 position, and the main dividing system table (5.2) rises to remove the dividing arms (5.4) from the case (A). At the same time, two parallel processes work together in order to ensure that the releasing tobacco bale remains in the case (A) without getting caught on the dividing arm blades (5.4) and without any tobacco pieces/blocks remains over these blades. For this purpose, the counter pressure plate (5.6) moves downward with the equal speed in the opposite direction, ensuring the smooth separation of the tobacco bale from system.

[0097] While the dividing arms (5.4) move upwards, the air control valve (5.7) connected to the small holes on the frame of the counter pressure plate (5.6) blows low pressure air from all these holes to prevent the spread of tobacco small particles and dust into the workspace during this physical movement. As next, this case (A) carrying the upper tobacco bale (C) is closed in the same way on the fifth conveyor (6).

[0098] The strip channels (6.1) on the fifth conveyor (6) allow the operator to easily tie the box (A) via strips (E). With the invention, a tobacco bale (B) in a case (A) has been divided into two equal parts and both parts have been packaged in cases (A). The cases (A) are steady packaged over the fifth conveyor (6) are unloaded from the system via the sixth conveyor (7) and the seventh conveyor (8).