Method for packaging products in boxes and packaging apparatus operating according to this method

Abstract

A method for packaging products in boxes comprises the steps of: a) providing a plurality of boxes in a folded configuration, b) collecting one box in the folded configuration and modifying the configuration thereof so as to bring it into an open configuration which is suitable for containing said products, c) verifying the conformity of the box in the open configuration with at least one predetermined quality parameter, and d) if the box in the open configuration complies with the quality parameter, introducing the products into the box, otherwise e) if the box in the open configuration does not comply with the quality parameter, returning the box to the folded configuration.

Claims

1. A method for packaging products in boxes, comprising: a) providing a plurality of boxes in a folded configuration, b) collecting one of said boxes in the folded configuration from said plurality and modifying the configuration thereof so as to bring it into an open configuration which is suitable for containing said products, c) verifying the conformity of said box in the open configuration with at least one predetermined quality parameter, and d) if said box in the open configuration complies with said at least one quality parameter, introducing said products into said box, while e) if said box in the open configuration does not comply with said at least one quality parameter, returning said box to the folded configuration, wherein the configuration of said box is modified from the folded configuration to the open configuration by an unfolding mechanism and from the open state to the folded state by the same mechanism which is operated in an opposite mode.

2. A method according to claim 1, wherein said box, once it has been returned to the folded configuration, is again brought into the open configuration, and then subjected to said steps c), d) or e).

3. A method according to claim 1, wherein said box, once it has been returned to the folded configuration, is rejected.

4. A method according to claim 1, wherein the configuration of said box is modified from the folded state to the open state by an unfolding mechanism and during said verification of conformity said box is maintained in engagement by said unfolding mechanism.

5. A method according to claim 1, wherein said quality parameter is a correct orientation of at least one lateral panel of said box.

6. A method according to claim 1, wherein said quality parameter is a correct orientation of at least one base panel which extends from a respective lateral panel of said box.

7. A method according to claim 1, wherein said box is brought into the open configuration by maintaining a lower lateral panel on a support plane and moving an upper lateral panel, which is opposite said lower lateral panel, away from said support plane, wherein said upper lateral panel is moved perpendicularly to said support plane, while said lower lateral panel is moved along said support plane.

8. A method according to claim 7, wherein said quality parameter is a correct orientation of at least one base panel which extends from a respective lateral panel of said box, and wherein said at least one base panel extends from said upper lateral panel of said box.

9. A method according to claim 7, wherein a correct orientation of a base panel which extends from said lower lateral panel of said box is controlled.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The characteristics and advantages of the present invention will become clearer from the detailed description of an embodiment shown, by way of non-limiting example, with reference to the appended drawings wherein:

(2) FIG. 1 is a partial schematic and top perspective view of a packaging apparatus for packaging products made in accordance with the present invention;

(3) FIG. 2 is a partial schematic and top perspective view of the packaging apparatus of FIG. 1 from another point of view;

(4) FIGS. 3 to 8 are schematic views of the packaging apparatus of FIG. 2 in successive operating positions;

(5) FIGS. 9 and 10 are partial schematic and side elevation views of the packaging apparatus of FIG. 1, in respective operating positions illustrating various components with respect to the previous figures;

(6) FIGS. 11 and 14 are partial schematic and side elevation views of the packaging apparatus of FIG. 1, in respective operating positions, illustrating additionally various components with respect to the previous figures;

(7) FIG. 15 is a schematic perspective view of a detail of the packaging apparatus of FIG. 1; and

(8) FIG. 16 is a schematic perspective view of the packaging apparatus of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

(9) With reference to the enclosed figures, 100 denotes as a whole a packaging apparatus made in accordance with the present invention.

(10) The packaging apparatus 100 is provided to package a plurality of products 1, loose, inside boxes 2 so as to prepare the final packaging for subsequent shipment.

(11) The products 1 are represented, in this preferred embodiment, by box-like packagings of capsules for the production of infusion type beverages, in particular coffee. In particular, each box-like packaging 1 contains a predefined number of capsules and is intended for retail sale.

(12) The packaging apparatus 100 comprises, in its more general units, a box formation station 10, where the boxes 2 are formed and provided to accommodate a group of products inside them, a station for composing the groups of products 20, in which the products 1 are suitably arranged in groups that are ready to be inserted into a box 2, and an insertion station 30, in which the groups of products 1 are inserted in the boxes 2.

(13) The boxes 2 are made of cardboard, in a completely conventional manner, and each of them comprises four lateral panels 3, 4, 5 and 6, joined one after the other, at their respective opposite sides defined by creases made in the cardboard, to form the lateral walls of the box 2. From each lateral panel 3, 4, 5 and 6, respective base panels 3a-3b, 4a-4b, 5a-5b and 6a-6b extend from opposite sides, which can oscillate with respect to the respective lateral panel at the crease joining them.

(14) In the folded configuration, the lateral panels are oscillated with respect to each other so that each lateral panel is coplanar to an adjacent lateral panel and folded overlapping with the other adjacent lateral panel, while the base panels extend from the respective lateral panels in a substantially coplanar manner with them, as clearly visible in the attached figures.

(15) The box formation station 10 comprises a supply unit of boxes 11, in which a stack of boxes 2 is stored in a folded configuration, as well as a gripping device 12, which is provided to collect one of the boxes 2 present in the supply unit of boxes 11 and to move it onto a carriage 13.

(16) The gripping device 12 preferably comprises an articulated arm 14, which is rotatable about several mutually parallel axes, at the free end of which a head provided with a plurality of gripping elements 15, which are arranged in several rows, is mounted.

(17) In particular, it is provided that the gripping elements 15 are positioned to retain the box 2 in a folded configuration at two of its adjacent and coplanar lateral panels, denoted with 3 and 4.

(18) The gripping elements 15 are preferably of the suction cup type, and are connected individually or in predefined groups to a depressurisation circuit to selectively retain the box 2 by suction.

(19) Naturally, the gripping device 12 can be made in a different manner, for example by mounting the gripping elements 15 on a robotic arm.

(20) The carriage 13 on which the box 2 collected by the gripping device 12 is deposited comprises a plurality of retention elements 16, which are provided to retain the box 2 in a folded configuration at the side opposite the gripping device 12.

(21) In particular, the retention elements 16 are mounted on bars 17 which are parallel to each other and, as a whole, define a support plane of the box 2 deposited by the gripping device 12.

(22) In the embodiment described herein, there are three bars 17 and extend at the base panels 5a and 6a, the lateral panels 5 and 6, and the base panels 5b and 6b, respectively.

(23) In different embodiments, the bars 17 can be in a different number, depending on the type and sizes of boxes 2 used in the packaging process. In particular, when the boxes 2 are relatively small in size, only 2 bars can be provided.

(24) Similarly to the gripping elements 15, the retention elements 16 are of the suction cup type, and are connected, individually or in predefined groups, to a depressurisation circuit to selectively retain the box 2 by suction.

(25) The carriage 13, moreover, is movable between a first position, in which it receives the box 2 in the folded configuration, and a second position, in which it delivers the box 2 in the open configuration to a conveyor device 40 which is provided to bring the box 2 in the open configuration to the insertion station 30 along an advance direction X.

(26) In particular, the carriage 13 is placed at one end of the conveyor device 40 opposite the insertion station 20 and its bars 17 extend parallel to the movement direction of the carriage, substantially coinciding with the advance direction X.

(27) On the carriage 13, at the side opposite the conveyor device, there is also provided an abutment element 18, which is useful both to facilitate the correct positioning of the box 2 on the carriage 13 and to ensure the correct movement of the box 2 during its passage from the folded configuration to the open configuration.

(28) The gripping device 12 and the carriage 13, thanks to their coordinated movement, form, as a whole, an unfolding mechanism which is provided to modify the configuration of the box 2 by bringing it from the folded configuration into the open configuration.

(29) In particular, the gripping device 12, once the box has been deposited in the folded configuration on the carriage 13 and after having deactivated the gripping elements 15 corresponding to the lateral panel 4, lifts vertically, moving away from the support plane defined on the carriage 13. At the same time, the carriage 13, after having deactivated the retention elements 16 corresponding to the lateral panel 6, moves from the first position towards the conveyor device 40. In this way, the lateral panels of box 2 are rotated between them around the respective creases until they reach a condition of mutual perpendicularity, defining the opening configuration of the box 2.

(30) In this configuration and with reference to the support plane and to the advance direction X, an upper lateral panel 3, a rear lateral panel 4, a lower lateral panel 5 (resting on the carriage 13) and a front lateral panel 6 (facing the conveyor device 40) can be identified in the box 2.

(31) The gripping device 12 and the carriage 13 also form, as a whole, a folding mechanism, since by performing the same movement in the opposite direction, they can modify the configuration of the box 2, by returning it from the open configuration to the initial folded configuration.

(32) The conveyor device 40 is of the step type, alternating movement steps with parking steps in the same position, and comprises a pair of transport belts 41, identical to each other, which are led in rotation along respective parallel and closed loop paths.

(33) Support elements 42 are mounted uniformly on both transport belts 41 and which are advantageously secured to the respective transport belt in two distinct points and provided to support the box 2 in an open configuration in its advancement along the advance direction X both at one of its front wall and at one of its rear wall.

(34) The distance and the dimensions of the transport belts 41 are such as to accommodate the central bar 17 of the carriage 13 between them, while the lateral bars 17 of the carriage 13 are placed side by side externally to the transport belts 41.

(35) When the carriage 13 is moved to the second position, i.e. towards the conveyor device 40, the transport belts 41 are interposed between the bars 17, whereas when the carriage 13 is moved to the first position, i.e. away from the conveyor device 40, the bars 17 are partially outside the transport belts 41.

(36) In the case of small-sized boxes 2, the transport belts 41 may be too close to allow a central bar to pass between them, so in this case, it is preferred that the carriage 13 provides only 2 lateral bars 17, which are placed side by side externally to the transport belts 41.

(37) On the sides of the conveyor device 40 there are also provided spreading arms 43, which can be moved in oscillation in order to abut the base panels 3a-3b and 5a-5b and to rotate them in extra-opening with respect to the respective upper and lower lateral panels 3 and 5.

(38) Immediately downstream of the spreading arms 43 there are also provided wings 44, sheet-like, which extend parallel to the plane of the conveyor device 40 and which are provided to maintain the respective base panels 3a-3b and 5a-5b in the extra-opening position as far as the insertion station 30.

(39) A first optical sensor 45 is also mounted at the initial end of each wing 44 and which is provided to verify the presence of the respective base panel 3a-3b and 5a-5b on the correct side of the respective wing 44.

(40) Further oscillating arms 46 are furthermore provided at the side of the conveyor device to rotate the base panels 4a and 6a inwardly of the box 2 perpendicularly to the respective lateral panels 4 and 6, so that the box 2 arrives at the insertion station 30 with the bottom partially formed.

(41) In a position beside the supply unit of boxes 11, the packaging apparatus 100 comprises a supply unit 21 which is provided to bring a row of products 1 to the composition station 20, where the products 1 are arranged in groups prepared for the insertion into a box 2 in an open configuration brought by the conveyor device 40 in the insertion station 30.

(42) The composition station 20 comprises a lifting device 22, which is positioned at the end of the supply unit 21 and provided to simultaneously lift a predefined number of products 1 as far as a bundling member 23 which is positioned above the supply unit 21. The bundling member 23 comprises lateral support shelves in order to retain the products 1 lifted by the lifting device 22 in place. Moreover, these support shelves are retractable so as to allow the row of retained products 1 to be lifted when a new row of products 1 is lifted by the lifting device 22, positioning itself under the row retained by the bundling member. In this way, a group of products 1 arranged in overlapping rows can be formed on the bundling member 23.

(43) The composition station 20 (represented in FIGS. 9 and 10) further comprises a movement device 24 which, upon completion of the predefined number of rows of products 1, pushes the group of products from the bundling member 23 as far as the insertion station 30.

(44) A second sensor 25 is further provided at the bundling member 23 and which is provided to detect the correct size of the group of products 1 before it is moved to the insertion station 30.

(45) In the insertion station 30, the groups of products 1 pushed by the movement device 24 are in alignment with a box 2 in the open configuration, and, by means of a further pushing member 31, the group of products 1 is introduced into the box 2 through an open base thereof.

(46) For this purpose, a pair of oscillating arms 32 are further envisaged in the insertion station 30 and which are provided to open the base panels 4b and 6b before insertion of the group of products 1 and then to close them again as soon as the group of products 1 is introduced.

(47) Downstream of the insertion station 30, there is provided a closing unit 35 where the boxes 2, containing the products 1, are closed and sent for shipment. In particular, the closing unit 35 comprises adhesive dispensers (not represented) which are provided to apply glue dots on the base panels 4a, 4b and 6a, 6b, already rotated into the closing position of the bases of the box 2.

(48) The closing unit 35 further comprises arms 36 which are mounted on supports 37 placed at the sides of the conveyor device 40 and which can be moved to rotate the base panels 3a, 3b and 5a, 5b inwardly of the box 2, perpendicularly to the respective lateral panels 3 and 5, and to push them against the base panels 4a, 4b and 6a, 6b respectively (on which glue dots are applied) so as to close the bottom and the top of the box 2.

(49) In order to facilitate the correct closing operation of the base panels 3a, 3b and 5a, the closing unit 35 further comprises a squaring device (not represented) for squaring the box 2. The squaring device comprises fingers that extend vertically from the top towards the conveyor device 40 and that are provided to abut the front and rear lateral panels 4 and 6 at their upper region and keep them in a condition of perpendicularity with respect to the lower and upper lateral panels 3 and 5. These fingers can advantageously be oscillated to allow the box 2 to enter and exit the closing unit 35 and, preferably, are mutually positioned at an adjustable distance, so as to perform their function on boxes of different sizes.

(50) The squaring device is provided to oscillate the fingers against the lateral panels 4 and 6 before the base panels 3a, 3b and 5a, 5b are pushed by the arms 36 against the base panels 4a, 4b and 6a, 6b, so that the box 2 is perfectly squared before its final closure.

(51) The packaging apparatus 100 further comprises a first rejection station 50 (represented in FIGS. 11 to 14), which is provided to reject any boxes 2 that are not conforming upon a verification of their correct opening, as described in more detail below.

(52) The first rejection station 50 is positioned near the carriage 13 at the side opposite the conveyor device 40, substantially under the supply unit of boxes 11 and comprises a pair of motorised belts 51 which in cooperation with respective upper contrast rollers 52, are provided to transport the box 2 in a folded configuration away from the carriage 13, for example towards a discharge container (not represented).

(53) The packaging apparatus 100 further comprises a second rejection station 55, which is provided to reject any groups of products 1 that are not conforming upon a verification of their correct composition, as described in more detail below.

(54) The second rejection station 55 is positioned at the side of the insertion station 30, at the side opposite the movement device 24, and comprises a pusher element 56 which is provided to push the group of products to be rejected into a discharge container 57.

(55) In the packaging apparatus 100, there is also provided a third rejection station, which is positioned on the supply unit 21 of the products 1 upstream of the composition station 20, as well as a fourth rejection station 58 which is positioned downstream of the closing station 35.

(56) In particular, the third rejection station is provided to reject any products 1 that are incorrectly positioned on the supply unit 21, for example rotated on themselves. The correct positioning of the products on the supply unit 21 can be controlled in line, for example by means of an optical sensor, and in the event of non-conformity, a rejection member, for example a lateral diverter, can be commanded, which removes the non-conforming product from the supply unit 21.

(57) The fourth rejection station 58, on the other hand, is provided to reject any boxes 2 containing a group of products 1 that are not packaged correctly, for example due to a failure to glue the base panels.

(58) The packaging apparatus 100 further comprises a control unit (not represented in the figures) which is provided to receive and process the signals received from the sensors or from the operator and to consequently command the movement of the various components of the apparatus according to a programmed operating mode described below.

(59) In an initial configuration of the packaging apparatus (FIGS. 1 and 2), the carriage 13 is in the first position, spaced apart from the conveyor device 40 which, in turn, is stationary in a position of waiting for a box in the open configuration, with a first support element 42 ready to abut a front wall of this box (in this example represented by the front lateral panel 6) and a second support element 42 which is ready to abut a rear wall of this box (in this example represented by the rear lateral panel 4) not yet rotated by the respective transport belt 41, so as to result at a level just below the support plane of the carriage 13 and not to hinder the subsequent movement of the box 2 towards the conveyor device 40.

(60) The gripping device 12 then collects a box 2 in the folded configuration from the supply unit of boxes 11, retaining the adjacent lateral panels 3 and 4 with its gripping elements 15 (FIG. 3), and deposits it on the carriage 13, on the support plane defined by its retention elements 16 (FIG. 4) which retain the box at both the lateral panels 5 and 6 and the respective base panels 5a, 5b and 6a, 6b.

(61) In this position, the box 2 in the folded configuration has one of its joining side between the lateral panels 3 and 6 which is substantially lying against the support element 42 while the opposite side, joining the lateral panels 4 and 5 is substantially lying against the abutment element 18.

(62) At this point, the gripping device 12 and the carriage 13, after having selectively deactivated the gripping and retention elements corresponding to the lateral panels 4, 6 and to the base panels 6a and 6b, are moved as described above to modify the configuration of the box 2 and to bring it into the open configuration (FIGS. 5 and 6).

(63) Once the opening of the box 2 has been completed, the conveyor device 40 is set in motion along the advance direction X and simultaneously the gripping device 12 and the carriage 13 move together with it to keep the box 2 in a position lying against the support element 42. This simultaneous movement of the gripping device 12 and the carriage 13 allows the box 2 to be accompanied, keeping it in the correct open configuration, until the support element 42 has completed its rotation, placing itself close to the rear lateral wall 4.

(64) In the first step of this movement, the spreading arms 43 are actuated, which rotate the base panels 3a-3b and 5a-5b into extra-opening. In order not to hinder the opening of the latter, the lateral bars 17 of the carriage 13 disengage from the respective base panels and are lowered.

(65) The base panels 3a-3b and 5a-5b are then guided respectively above and below the wings 44, so as to maintain the extra-opening position given by the spreading arms (FIG. 7).

(66) At this point the first sensors 45 placed on the wings 44 detect the presence of the base panels 3a-3b and 5a-5b and, consequently, the control unit is able to verify whether the respective lateral panels 3 and 5 are correctly oriented and, ultimately, whether the box 2 has been opened correctly.

(67) If the verification is positive, then, the box is sent to the next steps of the packaging process, which envisage, as previously described, the advancement of the conveyor device 40, the rotation for closing the base panels 4a and 6a carried out by the oscillating arms 46, the arrival at the insertion station 30 where a group of products 1, which has been prepared in the meantime in the composition station 20, is introduced into the open box 2 and then the closure of the other base panels at the closing unit 35.

(68) If, on the other hand, the verification is negative, for example if any of the first sensors 45 does not detect the presence of the corresponding base panel, then the control unit will command the folding procedure of box 2.

(69) This involves moving the carriage 13 towards the first position and simultaneously lowering the gripping device 12, so as to repeat the movement made to open the box 2 in reverse (FIG. 11).

(70) In this way, the box 2 that has been returned in the folded configuration (FIG. 12) can be brought by the carriage 13 and by the gripping device 12 to the first rejection station 50 (FIG. 13). Here, in order to prevent the abutment element 18 from obstructing the passage of the box 2 towards the first rejection station 50, the carriage 13 is lowered, and the motorised belts 51 collect the box 2 and send it to a discharge container, while the gripping device 12 and the carriage 13, disengaged from the box 2, can restart the packaging cycle (FIG. 14).

(71) Alternatively, prior to rejection, the control unit may command the gripping device 12 and the carriage 13 to try to open again the box 2 and to bring it to a new control of the first sensors 45.

(72) The number of attempts to reopen box 2 is programmable, naturally taking into account production requirements.

(73) During the procedure of folding the box and the subsequent attempt to reopen it or to reject it, the group of products 1 prepared in the composition station 20 remains in position in the insertion station 30 waiting for the correctly opened box 2, which can be the same box of the first attempt or a new box.

(74) At the same time, in the composition station 20, thanks to the joint action of the lifting device 22 and the bundling member 23, the groups of products ready to be inserted in the box 2 in the open configuration are formed.

(75) Once the group of products has been formed on the bundling member 23, the second sensor 25 detects its height and/or any other significant dimension, so that the control unit can verify whether the group of products has been formed correctly.

(76) If the verification is positive, then the group of products 1 is moved by the movement device 24 at the insertion station 30, so that the pushing member 31 can insert it into the open box 2.

(77) If, on the other hand, the verification is negative, then the group of products 1 is moved by the movement device 24 as far as the second rejection station 55, where the pusher element throws the non-conforming group of products into the discharge container 57.

(78) The open box 2, present in the insertion station 30 waiting for the group of products 1 is meanwhile kept in position waiting for the next group of products formed by the composition station 20.

(79) Similarly, if the box 2 is the one that has to be rejected, it is the group of products 1 that will remain in position in the insertion station 30 waiting for a new box 2.

(80) It goes without saying that a person skilled in the art may, in order to meet specific and contingent application requirements, make further modifications and variants of the above-described present invention within the scope of protection as defined by the following claims.