Apparatus and method for checking a box containing one or several objects

Abstract

An apparatus (10) for checking a box (100) with an internal compartment (110) comprising a detection station (20) equipped with lateral sensors (22) arranged laterally on opposite sides with respect to the box (100) and configured to detect a lateral height (H) of the box (100), and further equipped with a plurality of upper sensors (25), arranged at a predetermined fixed height (ZD) above the box (100) and configured to detect a vertical distance (D) between the sensors and respective underlying points of the internal compartment (110), wherein it is provided to ascertain whether the box (100) is open or closed based on the comparison between the lateral height (H) detected by the lateral sensors (22) and the difference (F) between the fixed height (ZD) and the vertical distance (D) detected by the upper sensors (25).

Description

[0001] APPARATUS AND METHOD FOR CHECKING A BOX CONTAINING ONE

[0002] OR SEVERAL OBJECTS

[0003] FIELD OF THE INVENTION

[0004] The present invention concerns an apparatus and a method for checking a box containing objects of a different nature and size, capable of recognizing whether a box is open or closed and then closing and sealing any open boxes. The present invention can for example find application, without any limitation to generality, for sorting and / or packaging objects purchased in the context of e-commerce.

[0005] BACKGROUND OF THE INVENTION

[0006] In the context of plants for sorting and shipping objects that originate, for example, from online purchase orders, the objects associated with a given purchase order are arranged into empty boxes, which are closed thereon so as to then be sent to the address provided by the buyer.

[0007] Since each purchase order can concern various objects having different volumes, weights and sizes, the corresponding box has to be chosen appropriately.

[0008] For this reason, a plurality of boxes of different standardized formats are usually provided, which can be selected based on their containing capacity. The most appropriate box format can be chosen automatically, or by an operator.

[0009] In general, the boxes are made of cardboard, have four lateral walls, a base wall and a top wall. Both the base and top walls are formed by four flaps which, unless they are all the same, are two transverse flaps, typically connected to the short sides of the box, and two longitudinal flaps, connected to the long sides of the box.

[0010] Automated sorting plants known in the state of the art comprise a line for advancing the filled boxes, for example formed by one or more roller conveyors, along which several work stations are arranged.

[0011] These work stations comprise a detection station, in which it is provided to detect the box’s measurements so as to identify the box format to be worked, a closing station, in which folding members close first the transverse flaps and then the longitudinal ones, and a taping station, in which it is provided to seal the box with adhesive tape which, usually, is applied straddling the two longitudinal flaps.

[0012] A solution known in the state of the art, which describes a machine equipped with the aforementioned work stations for closing and sealing boxes of different formats, is described in US patent document published under publication number US 2011 / 0131925 Al.

[0013] Since the boxes in succession can have different formats, some solutions known in the art provide a centering station, in which it is provided to bring the box into a predetermined reference position on the advancement line that allows to execute the closing and taping operations correctly, regardless of the box’s format.

[0014] In some cases, the sorting plants known in the art also have to be able to manage the transit of already closed and sealed boxes on the advancement line, which pass through the work stations without the latter having to intervene on them. This is the case of boxes called “SIOC” in the sector, acronym of the English “Ships in Own Container”, in which the packaging is prepared directly by the objects’ manufacturer or distributor, and therefore do not need to be repackaged inside different boxes.

[0015] Today, e-commerce companies need to manage and process several thousand purchase orders a day, making it necessary to automate the management of sorting and shipping centers so as to guarantee as many packages as possible are processed.

[0016] A disadvantage of known sorting and shipping plants is the difficulty in making them fully automated, due to the many process variables to be taken into account, in particular the different formats of workable boxes and the fact that in some cases the boxes in transit may also have already been closed and sealed beforehand. In the latter case, it is preferable to avoid the operator having to pick up the box manually from the advancement line, before it reaches the closing station, and rest it on the advancement line again, downstream of the closing station. Even in the event the already closed box continues along the advancement line, it is necessary to prevent the adhesive tape from being applied again, both to avoid waste of material and also to avoid giving the box several layers of adhesive tape, which can make the box aesthetically unpleasant.

[0017] Another disadvantage of known sorting and shipping plants, and of the corresponding methods for packaging objects in a box, is that they are inefficient in terms of productivity.

[0018] Even the solution known from US 2011 / 0131925 Al is not able to process boxes automatically, discriminating whether the boxes in transit have already been closed and sealed so as to perform the necessary closing operations only on those that are still open.

[0019] There is therefore the need to perfect an apparatus and a method for checking a box containing one or several objects that can overcome at least one of the disadvantages of the state of the art.

[0020] To do this, it is necessary to resolve the technical problem of accurately and effectively detecting the sizes of the boxes and determining whether a box is open or closed, optimizing the apparatus’ operation, which is completely automated, and reducing its overall dimensions.

[0021] In particular, one purpose of the present invention is to provide an apparatus and perfect a method for checking a box, capable of simply and rapidly detecting the sizes of the box, establishing whether the box is open or closed on the basis of the measurements detected.

[0022] Another purpose of the present invention is to provide an apparatus and perfect a method for checking a box that are highly efficient and that lead to optimizing processing times so as to achieve high productivity, thanks to the complete automation of the operations to be performed on the box.

[0023] Another purpose of the present invention is to provide an apparatus and perfect a method for checking a box in which the operation of closing the top wall of the box is optimized as a function of the box’s detected length.

[0024] The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.

[0025] SUMMARY OF THE INVENTION

[0026] The present invention is set forth and characterized in the independent claims. The dependent claims describe other characteristics of the present invention or variants to the main inventive idea.

[0027] In accordance with the above purposes and to resolve the technical problem described above in a new and original way, also achieving considerable advantages compared to the state of the prior art, some embodiments described here concern an apparatus for checking a box having at least a pair of top folding flaps for closing the box and an internal compartment containing one or several objects.

[0028] According to one aspect, the apparatus comprises a conveyor configured to move the box on a supporting plane along an advancement direction through a closing station and a taping station which are configured to close the top flaps and then tape them, respectively, and a detection station arranged upstream of the closing and taping stations and equipped with lateral sensors configured to detect a lateral height of the box.

[0029] In accordance with another aspect of the present invention, the detection station comprises upper sensors, for example distance sensors, arranged on a support bar located above the box at a predetermined fixed height with respect to the supporting plane, wherein the upper sensors are configured to detect a vertical distance measured between the upper sensors and the box.

[0030] In accordance with another aspect of the present invention, the apparatus comprises a control and management unit connected to the lateral sensors and to the upper sensors, and comprising a data processing module to calculate a difference between the fixed height and the vertical distance detected by the upper sensors, and compare the lateral height detected by the lateral sensors with the calculated difference, wherein if the calculated difference is equal to the lateral height, the control and management unit deactivates the closing station and the taping station, making the box pass through the closing and taping stations without undergoing any closing and taping.

[0031] In accordance with another aspect of the present invention, the detection station further comprises additional sensors, configured to detect a position of the box on the supporting plane and a width of the box perpendicularly to the advancement direction.

[0032] In accordance with another aspect of the present invention, the control and management unit is configured to selectively activate a sub-set of the plurality of upper sensors which is aligned with and detects the box, based on the position and width of the box detected by the additional sensors.

[0033] In accordance with another aspect of the present invention, the additional sensors are at least a pair of sensors facing each other on opposite sides with respect to the advancement direction, and are configured to measure respective lateral distances between each additional sensor and a respective lateral wall of the box that is closer to the sensor.

[0034] In accordance with another aspect of the present invention, the control and management unit is configured to selectively activate the sub-set of sensors of the plurality of upper sensors located within a central space between the respective lateral distances.

[0035] In accordance with another aspect of the present invention, if the calculated difference is less than the lateral height, the processing module is further configured to determine a first height of the box in a closed configuration, through the formula Hl = H - LW / 2, where Hl is the first height, H is the measured lateral height and LW is the measured width. In this condition, the control and management unit is configured to position the closing and taping stations at a height suitable for closing and taping at the first determined height.

[0036] In accordance with another aspect of the present invention, the vertical distance detected by the upper sensors is calculated as an average value of the vertical distances detected by each sensor of the upper sensors.

[0037] In accordance with another aspect of the present invention, the apparatus comprises an inlet and an outlet between which the boxes are advanced by means of the conveyor.

[0038] In accordance with another aspect of the present invention, the apparatus comprises an abutment element, configured to temporarily block the advance of the box when it reaches the detection station.

[0039] In accordance with another aspect of the present invention, the abutment element is selectively positioned between a lowered position, in which it is below the supporting plane to allow the boxes to transit, and a raised position, in which it protrudes above the supporting plane to block the transit of the boxes.

[0040] In accordance with another aspect of the present invention, the lateral sensors are an emitter and a receiver, arranged laterally on opposite sides with the box therebetween.

[0041] In accordance with another aspect of the present invention, if the calculated difference is less than the lateral height, the control and management unit establishes that the box is open, with the at least a pair of top folding flaps in a raised position, and commands the closing and taping stations to close and tape the at least a pair of top folding flaps of the box.

[0042] In accordance with another aspect of the present invention, the apparatus further comprises centering members arranged in the closing station and configured to move the box into a reference position, along a transverse axis perpendicular to the advancement direction.

[0043] In accordance with another aspect of the present invention, the centering members comprise a plurality of rollers, preferably idle, configured to contact opposite lateral walls of the box, facilitating the advance of the box in the advancement direction.

[0044] In accordance with another aspect of the present invention, there is provided a method for checking a box having at least a pair of top folding flaps for closing the box and an internal compartment containing one or several objects.

[0045] In accordance with another aspect of the present invention, the method comprises the steps of:

[0046] - providing a closing station and a taping station configured to close the top flaps and then tape them, respectively,

[0047] - moving the box on a supporting plane along an advancement direction through the closing and taping stations,

[0048] - detecting a lateral height of the box by means of lateral sensors arranged upstream of the closing and taping stations,

[0049] - arranging upper sensors, for example distance sensors, on a support bar located above the box at a predetermined fixed height with respect to the supporting plane,

[0050] - detecting a vertical distance measured between the upper sensors and the box,

[0051] - calculating a difference between the fixed height and the vertical distance detected by the upper sensors,

[0052] - comparing the lateral height detected by the lateral sensors with the calculated difference.

[0053] In accordance with another aspect of the present invention, if the calculated difference is equal to the lateral height, the box is made to pass through the closing station and the taping station without undergoing any closing and taping, by deactivating the closing and taping stations.

[0054] In accordance with another aspect of the present invention, the method comprises a step of further detecting the position of the box on the supporting plane and a width of the box perpendicularly to the advancement direction by means of additional sensors, selectively activating a sub-set of the upper sensors which is aligned with and detects the box, based on the position and width of the box detected by the additional sensors.

[0055] In accordance with another aspect of the present invention, in which the boxes are of the type called “FEFCO 201”, the method comprises, if the calculated difference is less than the lateral height, a step of determining a first height of the box, corresponding to the height of the box in a closed configuration, through the formula: Hl = H - LW / 2, where Hl is the first height, H is the measured lateral height, and LW is the measured width. In this case, the closing and taping stations are positioned at a height suitable for closing and taping at the first determined height.

[0056] In accordance with another aspect of the present invention, if the calculated difference is less than the lateral height, the closing station and the taping station are commanded to close and tape the at least a pair of top folding flaps of the box.

[0057] In accordance with another aspect of the present invention, the step of detecting the vertical distance comprises calculating an average value of the vertical distances detected by each sensor of the upper sensors.

[0058] The apparatus and method according to the present invention allow to establish whether a box is open or closed through a simple control logic that provides a comparison of heights / distances detected by the sensors.

[0059] This allows to obtain an apparatus and a method able to sort, and possibly package, boxes at high speeds, in line with the sector’s need for very high productivity, able to manage hundreds or thousands of packages every day.

[0060] The apparatus and method according to the present invention are advantageously configured in such a way that, after having established that a box is closed, as for example in the case of the aforementioned SIOC boxes, the closing and taping stations are deactivated, thus optimizing their operation, so that the boxes are allowed to transit through them without undergoing any work by them.

[0061] The apparatus according to the present invention has an optimized layout that allows to reduce its overall dimensions.

[0062] DESCRIPTION OF THE DRAWINGS

[0063] These and other aspects, characteristics and advantages of the present invention will become apparent from the following description of some embodiments, given as a non-restrictive example with reference to the attached drawings wherein:

[0064] - fig. 1 is a schematic lateral view of an apparatus according to the present invention, shown in a first operating condition;

[0065] - fig. 2 is a schematic front view of the apparatus of fig. 1 , seen from the left, in the same operating condition;

[0066] - figs. 3, 5, 7, 9, 11, 13 and 15 are schematic lateral views, like those of fig. 1, which show successive operating conditions, defining an operating sequence of the apparatus;

[0067] - figs. 4, 6, 8, 10, 12, 14 and 16 are schematic front views, like those of fig. 2, which show successive operating conditions, defining an operating sequence of the apparatus;

[0068] - fig. 17 is a schematic lateral view of the apparatus of fig. 1 , shown in a different operating condition;

[0069] - fig. 18 is a schematic lateral view, like that of fig. 2, in which the apparatus is shown in the operating condition of fig. 17;

[0070] - figs. 19 and 20 are three-dimensional views of a box that can be worked using the apparatus of figs. 1-18 according to the present invention, in which the box is shown in an open condition and in a closed condition.

[0071] We must clarify that the phraseology and terminology used in the present description, as well as the figures in the attached drawings also in relation as to how described, have the sole function of better illustrating and explaining the present invention, their purpose being to provide a non-limiting example of the invention itself, since the scope of protection is defined by the claims.

[0072] To facilitate comprehension, the same reference numbers have been used, where possible, to identify identical common elements in the drawings. It is understood that elements and characteristics of one embodiment can be conveniently combined or incorporated into other embodiments without further clarifications.

[0073] DESCRIPTION OF SOME EMBODIMENTS

[0074] With reference to figs. 1-18, an apparatus 10 is described for closing and sealing boxes 100 comprising an internal compartment 110 configured to contain one or several objects 200.

[0075] The apparatus 10 can be used in the context of automated sorting and packaging plants used by e-commerce companies, but also in other contexts.

[0076] The sizes of the boxes 100 are chosen according to the shape and size of the objects 200 that can be inserted therein. The sorting and packaging plants used in the e-commerce sector are configured to work a given, predetermined number of standardized box formats, from which the most suitable format is chosen on each occasion based on the objects to be contained.

[0077] In the example of figs. 19-20, each box 100 comprises a base wall 101, an opposite top wall 102 and four lateral walls 103, 104.

[0078] Since usually each box 100 has, in a plan view, a rectangular shape, it comprises two opposing smaller lateral walls 103, and two opposing larger lateral walls 104 perpendicular to the smaller lateral walls. The lateral walls 103 and 104 are connected by vertical edges 105.

[0079] The base wall 101 and the top wall 102 are formed by four folding flaps: two transverse flaps 106, each joined to a respective smaller lateral wall 103, and two longitudinal flaps 107, each joined to a respective larger lateral wall 104.

[0080] The longitudinal flaps 107 of both the base wall 101 and also the top wall 102 are joined by a strip of adhesive tape 108, arranged longitudinally so as to clamp the flaps together and anchor them to the smaller lateral walls 103.

[0081] For greater clarity in the disclosure, hereafter we will refer to a longitudinal axis X, a transverse axis Y and a vertical axis Z, which are oriented with respect to each other in such a way as to form a set of three Cartesian axes.

[0082] The boxes 100 are conveyed toward an inlet of the apparatus 10 and away from an outlet thereof through a conveyor 11.

[0083] The conveyor 11 is configured to move the boxes 100 along an advancement direction A on a substantially horizontal supporting plane P.

[0084] The conveyor 11 can be integrated in the apparatus 10, or be autonomous and independent thereof, being limited to serving it so as to take the boxes to it and then make them leave it.

[0085] The conveyor 11 advances the boxes 100 from an inlet 12 to an outlet 13 of the apparatus 10.

[0086] The advancement direction A is preferably parallel to the longitudinal axis X. The conveyor 11 advances the boxes 100 along the advancement direction A, with the boxes oriented in such a way that the larger lateral walls 104 are parallel to the longitudinal axis X and the smaller lateral walls 103 are parallel to the transverse axis Y. The conveyor 11 can comprise a pair of lateral panels that delimit it laterally. In addition, it is possible to define a longitudinal axis of symmetry S of the apparatus that is equidistant from the lateral panels and parallel to the longitudinal axis X.

[0087] The conveyor 11 defines a transverse width W, parallel to the transverse axis Y and sized so as to allow the transit of the box 100 having the maximum standardized format, among those the apparatus 10 is able to work.

[0088] The conveyor 11 can comprise conveyor chains or belts or aprons, or a plurality of rollers arranged with their axes parallel to each other so as to form a roller conveyor, of a type known in the art.

[0089] The conveyor 11 can be motorized, for example by means of a suitable actuator device, not shown, comprising an electric motor for example. In the event that the conveyor 11 is configured as a roller conveyor, the electric motor can make some rollers rotate, while the rotation of other rollers can be achieved by using other motors so as to have different segments of roller conveyor motorized independently, according to configurations known in the art.

[0090] The apparatus 10 comprises a detection station 20 for detecting the sizes of the box 100.

[0091] The detection station 20 comprises one or more lateral sensors 22, arranged laterally with respect to the box 100, typically on opposite sides with respect thereto.

[0092] The lateral sensors 22 are configured to detect the sizes of the box 100 in the direction of the vertical axis Z.

[0093] The detection station 20 can further comprise additional sensors 23, configured to determine the position of the box 100 on the supporting plane P and the width of the box, in particular by detecting the distance between the sensor and a wall of the box along the transverse axis Y, in particular the larger lateral wall 104.

[0094] The lateral sensors 22 comprise an emitter and a receiver, and are preferably aligned with each other along the transverse axis Y.

[0095] The additional sensors 23 are at least a pair of sensors facing each other on opposite sides of the box 100 with respect to the advancement direction A. These sensors are for example configured as photocells or distance sensors, and are preferably offset in the direction of the longitudinal axis X, so that the two sensors of the pair are not arranged exactly facing each other. The additional sensors 23 detect the lateral distances Yl, Y2 (fig. 4) parallel to the transverse axis Y that run between each sensor and the larger lateral wall 104 arranged in front of it.

[0096] In a variant embodiment, a single sensor can be provided that integrates these functions.

[0097] Each sensor 22, 23 is arranged on a respective support 24, on both sides of the box 100.

[0098] In one embodiment, the sensors 22 and 23 are arranged close to each other, for example supported by the same support.

[0099] The detection station 20 comprises a plurality of upper sensors 25, arranged on a support bar 26 located above the box 100, at a predetermined fixed height ZD with respect to the supporting plane P.

[0100] In the example shown, the detection station 20 comprises seven upper sensors 25; it is however clear that a different number of sensors can be provided in other embodiments. In general, the number of sensors required is a function of the width W of the conveyor 11 and of the sensors’ performance characteristics.

[0101] The upper sensors 25 can be distance sensors arranged according to a linear or bi-linear array configuration.

[0102] Each upper sensor 25 is configured to detect a vertical distance D, parallel to the vertical axis Z, between the sensor and a respective underlying point of the internal compartment 110.

[0103] In the example shown, the support bar 26 is arranged parallel to the transverse axis Y.

[0104] The upper sensors 25 are homogeneously distributed on the support bar 26, in such a way that their field of view extends over the entire width W of the conveyor 11, or a substantial part of it, for example a portion greater than half, or three quarters, of the width W.

[0105] The detection station 20 comprises an abutment element 27, configured to temporarily block the advance along the conveyor 11 of the box 100 that reaches the detection station 20 on each occasion.

[0106] In addition, the function of the abutment element 27 is to correct any misalignments, that is, to re-position the box 100, because the action of the conveyor 11 , for example the rotation of the rollers in the event that the conveyor is a roller conveyor, pushes the box toward the abutment element 27 so as to bring the smaller lateral wall 103 into contact with the abutment element 27, even if the box 100 were to reach the detection station 20 with a different orientation, for example with its lateral walls 103, 104 rotated by a few degrees with respect to the longitudinal and transverse axes X and Y.

[0107] The abutment element 27 can be selectively driven between a raised position, in which it protrudes above the supporting plane P of the boxes 100 on the conveyor 11 so as to abut against the box, and a lowered position, in which it is instead below the supporting plane P to allow the boxes to transit.

[0108] When the abutment element 27 is in the raised position, it is configured so that the box 100 abuts against it, in particular with its smaller lateral wall 103, which is arranged parallel to the abutment element 27.

[0109] In the example shown, the abutment element 27 is oriented parallel to the transverse axis Y.

[0110] The sensors 22, 23 and the upper sensors 25 are arranged upstream of the abutment element 27, with reference to the advancement direction A of the boxes 100, so that they can perform the detections described above while the box 100 is temporarily stopped against the abutment element 27.

[0111] This ensures that the box is oriented correctly so as to have greater accuracy and precision of the measurements carried out.

[0112] The apparatus 10 further comprises a closing station 30 of the boxes 100, configured to close the transverse and longitudinal flaps 106, 107 so as to form the top wall 102.

[0113] The closing station 30 is arranged downstream of the detection station 20, with reference to the advancement direction A, in particular downstream of the abutment element 27.

[0114] The closing station 30 comprises an additional abutment element 31, configured to temporarily block the advance along the conveyor 11 of the box 100 that is located in the closing station 30 on each occasion.

[0115] The additional abutment element 31 can be selectively driven between a raised position, in which it protrudes above the supporting plane P of the boxes 100 so as to abut against the box, and a lowered position, in which it is instead below this plane and allows the boxes to transit. The closing station 30 comprises a movable frame 32, which can be raised or lowered with respect to the supporting plane P parallel to the vertical axis Z.

[0116] In the example given here, the movable frame 32 comprises a first horizontal arm 33 and a second horizontal arm 34, connected to each other and arranged perpendicularly to each other.

[0117] The closing station 30 comprises a plurality of closing devices 35, 36, 37, 38, each configured to bring a respective transverse or longitudinal flap, 106 or 107, of the box 100 from a vertical or inclined position (open box), to a substantially horizontal position (closed box), in the manner that will be explained in detail below.

[0118] A front closing device 35 is attached to the movable frame 32, substantially above the additional abutment element 31. In particular, the front closing device 35 is attached to the first horizontal arm 33 by means of a support structure 39.

[0119] The front closing device 35 is configured to strike the front transverse flap 106 connected to the front smaller lateral wall 103, that is, the one facing the outlet 13.

[0120] The front closing device 35 comprises a front contact element 40, rotatable around an axis that is parallel to the transverse axis Y by about 90°, between a vertical or resting position, in which the front contact element 40 waits for the box 100 to be positioned against the additional abutment element 31, and a horizontal position, in which the front contact element 40 strikes the transverse flap 106 and accompanies it from the vertical position to the horizontal position.

[0121] The front contact element 40 can also be configured to keep the longitudinal flaps 107 reciprocally neared, in their horizontal position, during the passage toward the next work station, as will be better explained in the description of the operation of the apparatus 10.

[0122] The closing station 30 comprises two lateral closing devices, indicated with reference numbers 36 and 37, respectively, configured to interact with the two longitudinal flaps 107. In the example given here, the lateral closing devices 36, 37 are shaped as L-shaped arms.

[0123] The lateral closing devices 36, 37 are attached to the movable frame 32 with a degree of freedom of movement with respect thereto. In particular, the lateral closing devices 36, 37 are attached to the first horizontal arm 33 and translate thereon with an alternating movement parallel to the transverse axis Y, as indicated for example by the arrows in fig. 14.

[0124] In the embodiment described here, the lateral closing devices 36, 37 complete a forward stroke, in which they move from a position arranged in proximity to the lateral panels of the conveyor 11 to a position arranged in proximity to the axis of symmetry S, and a return stroke, in which they perform the opposite movement. During the forward stroke, the lateral closing devices 36, 37 move with a movement that brings them closer to each other, while during the return stroke they move with a movement that moves them away from each other.

[0125] In the example described here, the lateral closing devices 36, 37 encounter a respective longitudinal flap 107 during the forward stroke in which, as they advance, they accompany it toward the horizontal position.

[0126] The closing station 30 comprises a rear closing device 38, configured to strike the rear transverse flap 106 connected to the rear smaller lateral wall 103, that is, the one facing the inlet 12.

[0127] The rear closing device 38 comprises a rear contact element 41 , rotatable around an axis parallel to the transverse axis Y by about 90° between a vertical, or resting, position, in which the rear contact element 41 does not interact with the box 100 that is arriving into the closing station 30, and a horizontal position, in which the rear contact element 41 strikes the transverse flap 106 and accompanies it from the vertical position to the horizontal position.

[0128] The rear closing device 38 is configured so as to give the rear contact element 41 two degrees of freedom of movement, which are added to a third degree of freedom of movement which consists of the aforementioned rotation of the rear contact element 41 around the transverse axis Y.

[0129] These two degrees of freedom of movement allow the rear contact element 41 to translate both parallel to the longitudinal axis X and also parallel to the vertical axis Z.

[0130] In the example described here, in order to give the rear contact element 41 the two degrees of freedom of movement, the closing station 30 comprises a vertical arm 42 on which the rear closing device 38 supporting the rear contact element 41 is vertically slidable, parallel to the vertical axis Z.

[0131] The vertical arm 42 is horizontally slidable on the second horizontal arm 34 of the movable frame 32, parallel to the longitudinal axis X. In other embodiments, other equivalent structures capable of giving the rear contact element 41 the two degrees of freedom of movement can be provided. For example, a robotic articulated arm can be provided having at least three degrees of freedom of movement, which supports, at the free end of the kinematic chain, the rear contact element 41.

[0132] The closing station 30 comprises a sensor 45, for example a suppression distance sensor, configured to detect a length L of the box 100, measured parallel to the longitudinal axis X, approaching the box when it is stationary, in contact with the additional abutment element 31 , as will be explained in more detail below.

[0133] The sensor 45 can be installed on board the rear closing device 38, for example on the vertical arm 42.

[0134] In alternative embodiments, not shown, the sensor 45 can be installed in different positions, for example on a dedicated support, in proximity to one of the lateral panels.

[0135] The closing station 30 further comprises centering members 46, configured to move the box 100 along the transverse axis Y in such a way that an ideal line of symmetry of the box 100 is brought to coincide with the longitudinal axis of symmetry S. In the example shown, the centering members 46 are configured as two rod-like elements parallel to the longitudinal axis X.

[0136] The centering members 46 each comprise a plurality of rollers 47, preferably idle, configured to contact the larger lateral walls 104 and facilitate their advance along the advancement direction A.

[0137] Preferably, two centering members 46 are provided, mechanically constrained to each other so as to move synchronously.

[0138] In a resting condition, the centering members 46 are arranged in proximity to the lateral panels and, when it is necessary to center a box 100, are activated to move toward the axis of symmetry S.

[0139] The extent of the travel of the centering members 46 is a function of the measurements of the box 100 that have previously been detected in the detection station 20.

[0140] The closing station 30 comprises a conveyor member 48, for example provided with one or more pushing teeth 49 and driven by its own motor, configured to block the box 100 arriving in the closing station 30 against the additional abutment element 31. The pushing teeth 49 are configured to engage against the rear smaller lateral wall 103, facing the inlet 12, so as to push the box 100 in the advancement direction A.

[0141] The apparatus 10 further comprises a taping station 50, arranged downstream of the closing station 30.

[0142] The taping station 50 comprises one or two applicator units 51, arranged one above and one below the conveyor 11, to apply a strip of adhesive tape 108 on the top wall 102 and on the base wall 101, respectively.

[0143] The adhesive tape 108 is applied on the box 100 in a predetermined position, along the longitudinal axis X, in order to join the longitudinal flaps 107 and attach them to the smaller lateral walls 103. In this way, it is possible to close the box 100 firmly and securely.

[0144] The two applicator units 51 can be driven independently of each other, in particular only one of the two applicator units can be activated, for example the one above the conveyor 11, in the event that the base wall 101 has already been closed with adhesive tape before entering the apparatus 10.

[0145] In alternative embodiments, not shown, in which the apparatus 10 is configured to work boxes 100 in which the base wall 101 has already been closed with the adhesive tape 108, the taping station 50 comprises only one applicator unit 51, in particular the one arranged above the supporting plane P of the boxes 100.

[0146] The applicator unit 51 arranged above the conveyor 11 is mounted on a structure movable vertically along the vertical axis Z, so as to bring the unit to the correct height as a function of the height of the box 100 being worked. In the example shown by way of a non-limiting example, the applicator unit 51 is installed on the support structure 39 that also supports the front closing device 35.

[0147] In an alternative embodiment, the applicator unit 51 is supported by a dedicated support structure, different from the support structure 39 as long as the dedicated support structure is a structure vertically movable along the vertical axis Z that allows to bring the applicator unit 51 to the correct height as a function of the height of the box 100 being worked.

[0148] The apparatus 10 comprises a control and management unit 60 configured to command its operation.

[0149] In particular, the control and management unit 60 communicates with the apparatus’ 10 sensors, in particular with the sensors 22, 23, the upper sensors 25 and the sensor 45, to receive the measurements detected thereby.

[0150] The control and management unit 60 comprises a data processing module 61 configured to process the data received from the sensors so as to establish whether the box 100 is open or closed, in the manner explained in more detail below.

[0151] The control and management unit 60 then also communicates with the driving members, of a known type and not shown, which determine the movement of the apparatus’ movable parts, in particular the abutment elements 27, 31, the movable frame 32, the closing devices 35-38 and the front and rear contact elements 40, 41 comprised therein, the centering members 46, the conveyor member 48 and the applicator units 51.

[0152] The control and management unit 60 comprises an internal database in which the standardized formats of boxes 100 that can be worked by the apparatus 10 are stored. For each box format, the database stores the length L, width LW, and height H.

[0153] In this way, according to some embodiments, the processing module 61 can also carry out checks on the measurements detected by the sensors 22 and 23 and by the sensor 45 (which detects the length), once at least two datums are known, so as to verify that the third corresponds to the expected one.

[0154] Thanks to this comparison, the apparatus 10 can operate at even higher speeds, so as to process a greater number of boxes 100 in a given unit of time. In fact, the operator could choose an operating mode whereby it is possible to avoid checking the length L by means of the sensor 45 located on the rear closing device 38, at least for some boxes, since this value is retrieved from the database once the height H and the width LW have been detected.

[0155] The operation of the apparatus 10 is described below, which corresponds to the method for packaging a box containing one or several objects according to the present invention.

[0156] The method comprises a first advancement step, in which the box 100 is advanced along the advancement direction A, on the supporting plane P, up to the detection station 20 (figs. 1 -4).

[0157] In the first advancement step, the box 100 advances until its front smaller lateral wall 103 abuts against the abutment element 27, which is arranged in its raised position (fig. 3).

[0158] The method then comprises a first step of detecting the measurements of the box 100.

[0159] This first detection step comprises detecting the lateral height H, the position and the width of the box by means of the lateral sensors.

[0160] In particular, the lateral sensors 22 detect the lateral height H of the box 100 and the additional sensors 23 detect its width LW.

[0161] In particular, the processing module 61 calculates the width LW of the box 100 as the difference between the reciprocal distance between the additional sensors 23, approximately equal to the width W, and the sum of the lateral distances Yl, Y2 (fig. 4) detected by these sensors.

[0162] The upper sensors 25 detect the vertical distance D spanning between each sensor and a respective underlying point arranged within the perimeter of the box 100, that is, in the volume corresponding to the internal compartment 110.

[0163] In some embodiments, the vertical distance D is calculated by the processing module 61 as the average value of the vertical distances detected by each of the upper sensors 25.

[0164] According to some embodiments, the method provides to selectively activate only a sub-set of the upper sensors 25, depending on the position of the box 100.

[0165] In this embodiment, the method provides to activate only one or several sensors, in particular those arranged above the internal compartment 110 of the box 100, that is, in the segment of support bar 26 comprised between the lateral distances Yl, Y2, that is, the segment that extends for a portion equal to the width LW of the box 100, exactly above it.

[0166] In this case, the upper sensors 25 arranged as the outermost in the row of sensors that are located above the distances Yl and Y2 may therefore not be activated.

[0167] In this case, the vertical distance D is calculated as the average value of the distances detected only by the sensors that have been activated.

[0168] The processing module 61 then calculates a difference F between the fixed height ZD and the vertical distance D detected by the upper sensors 25, and compares it with the lateral height H of the box 100 detected by the lateral sensors 22.

[0169] As a result of the comparison, the control and management unit 60 establishes that the box 100 is closed if the calculated difference F is equal to the lateral height H, while it establishes that the box 100 is open if the calculated difference F is less than the lateral height H.

[0170] We must clarify that a second height H2 of the longitudinal and transverse flaps 106, 107 which - in the event they are raised with respect to the horizontal plane - are arranged so as to have an overall vertical dimension component, is equal to half of the width LW of the box.

[0171] In the event that the control and management unit 60 has established that the box 100 is already closed, it deactivates the closing 30 and taping 50 stations, through which the box 100 passes without undergoing any work (closing and taping), since the box 100 is already closed and sealed with the adhesive tape, as in the example shown in figs. 17-18.

[0172] In one embodiment, the deactivation of the closing 30 and taping 50 stations provides that the control and management unit 60 commands the movable frame 32 and the support structure 39 that supports the applicator unit 51 arranged above the conveyor 11 to rise completely, translating along the vertical axis Z so as not to interfere with the transit of the already closed box 100. In addition, the control and management unit 60 commands the lateral closing devices 36, 37 to remain in the reciprocally distanced position, furthest away from the axis of symmetry S.

[0173] In an alternative embodiment, deactivating the closing station 30 does not provide the deactivation of the centering members 46. In this case, the apparatus 10 allows to also bring the boxes 100 in transit that have already been closed previously into the reference position.

[0174] According to another embodiment, alternative to the previous one, the raising of the movable frame 32 and of the movable structure provides to translate them vertically along the vertical axis Z by a magnitude that is a function of the height H, in particular by a magnitude slightly higher than such height, so as to optimize their movement while still allowing the transit of the already closed box 100.

[0175] In the event that the control and management unit 60 has established that the box 100 is open, the processing module 61 determines a first height Hl, corresponding to the height of the box in the closed configuration, which in fact corresponds to the height of the lateral walls 103, 104.

[0176] If the box is of “FEFCO 201” type, the first height Hl can be determined through the formula:

[0177] Hl = H - LW / 2 where Hl is the first height of the box, H is the measured lateral height of the box, and LW is the measured width of the box.

[0178] A second height H2 of the longitudinal and transverse flaps 106, 107, however, is already known, once the type of box is known. In the case of the aforementioned “FEFCO 201” type, the second height H2 is equal to half the width LW of the box 100.

[0179] In this case (open box), the method comprises a second advancement step, after the abutment element 27 has been brought into its lowered position (figs. 5-6).

[0180] The second advancement step advances the box 100 on the supporting plane P, along the advancement direction A, until the front smaller lateral wall 103, that is, the one facing the outlet 13, abuts against the additional abutment element 31 (figs. 7-8).

[0181] The second advancement step is performed by means of the conveyor member 48.

[0182] The control and management unit 60 commands the movement of the conveyor member 48 so that the positioning of the pushing tooth 49 with respect to the rear smaller lateral wall 103 is correlated to the length L of the box 100 detected by the sensor 45.

[0183] An optional centering step is provided during the second advancement step, in which the centering members 46 move along the transverse axis Y (fig. 8) to bring the box 100 into a reference position, in which the longitudinal axis of symmetry of the box 100, which substantially coincides with the line separating the two longitudinal flaps 107, is brought to coincide with the longitudinal axis of symmetry S.

[0184] The control and management unit 60 commands the drive of the centering members 46 as a function of the width LW of the box 100 previously determined in the detection step, thanks to the measurements detected in the detection station 20, in particular by means of the additional sensors 23.

[0185] The centering members 46, thanks to the presence of the rollers 47, accompany the advance of the box 100 through the closing station 30 and toward the subsequent taping station 50, once the closing step described below has ended. After the second advancement step, the method comprises a step of positioning the rear closing device 38, which is brought into the correct position to interact with the rear transverse flap 106 (figs. 9-10). This position is variable at least as a function of the length L of the box 100, more preferably also as a function of the determined first height Hl of the lateral walls 103, 104.

[0186] The length L of the box 100 is detected by the sensor 45 while the box is stationary against the additional abutment element 31. In particular, it is provided that when the sensor 45 reaches a certain known and predetermined distance from the box 100 (thanks to the movement of the rear closing device 38 approaching the box), it sends a signal to the control and management unit 60 which calculates the length L knowing both the spatial parameters of the closing station 30 (for example, the distance between the point at which the signal is transmitted and the additional abutment element 31), and also the amount of time elapsed from when the rear closing device 38 moved from its stop position PS to the moment the signal was transmitted.

[0187] Normally, the rear closing device 38 is positioned in a predetermined stop position PS. In this stop position PS, the rear closing device 38 is positioned in an end-of-travel position higher than the vertical arm 42 and in a rearward end-of- travel position, which is the position closest to the detection station 20 and furthest from the taping station 50, with respect to the second horizontal arm 34 of the movable frame 32.

[0188] Based on the value of the length L of the box 100 detected by the sensor 45 at the end of the second advancement step, or alternatively retrieved from the database once the lateral height H and the width LW are known, and on the first height Hl determined, for example, as described above, the control and management unit 60 communicates the coordinates in the X-Z plane to which the rear closing device 38 has to be brought. As a function of these coordinates, both the vertical translation along the vertical axis Z of the rear closing device 38 on the vertical arm 42, as well as the horizontal translation along the longitudinal axis X of the vertical arm 42 along the second horizontal arm 34 are commanded (figs. 9- 10).

[0189] The combination of these two translational movements along the X-Z axes can result in a rectilinear, curvilinear or mixtilinear trajectory of the rear closing device 38, with which the latter moves from the stop position PS to the X-Z coordinates communicated by the control and management unit 60.

[0190] The method then comprises a closing step, comprising in turn a first sub-step, in which the front and rear contact elements, 40 and 41 respectively, bring the transverse flaps 106 into the horizontal position (figs. 11-12), and a second substep, in which the lateral closing devices 36, 37 bring the longitudinal flaps 107 into the horizontal position (figs. 13-14).

[0191] At the end of the first sub-step, the rear closing device 38 returns to the stop position PS and the front and rear contact elements 40 and 41 return to the vertical position, while at the end of the second sub-step the lateral closing devices 36, 37 return to their reciprocally distanced position, as shown in figs. 15-16.

[0192] We must clarify that during the closing step the next box is already in the detection station 20 (fig. 13) therefore, after the box being closed exits the closing station 30, the movable frame 32 is brought to the correct vertical height to be able to correctly close the next box, on the basis of the lateral height H value just detected in the detection station 20. tn some embodiments, the method can provide to keep the front contact element 40 in its horizontal position also during the second sub-step. tn these embodiments, the front contact element 40 advantageously also acts as an abutment element that keeps the longitudinal flaps 107 in the correct horizontal position, preventing them from being able to rise again before the taping step. In this case, it is advantageous that the front contact element 40 is arranged close to the taping station 50. The front contact element 40 keeps the longitudinal flaps 107 blocked in position until the application of the adhesive tape by the applicator unit 51, so as to avoid the risk of incorrect or inaccurate application of the adhesive tape caused by the accidental rising of the longitudinal flaps 107 after the closing step.

[0193] Subsequently, a further advancement step is provided in which the pushing tooth 49 pushes the box 100 in the advancement direction A toward the taping station 50.

[0194] Here, the method provides a step of applying the adhesive tape (figs. 15-16), in which the applicator units 51 apply the adhesive tape to close the top wall 102 and possibly the base wall 101, applying a strip of adhesive tape 108 that joins the longitudinal flaps 107.

[0195] In some embodiments, in which the base wall 101 has already been closed previously with the adhesive tape, the control and management unit 60 commands the activation of only the applicator units 51 arranged above the conveyor 11.

[0196] In other embodiments, in which the adhesive tape 108 has to be applied on both the base 101 and top 102 walls, the control and management unit 60 commands the activation of both applicator units 51.

[0197] After the adhesive tape application step, the box 100 continues to advance on the conveyor 11 until it reaches the outlet 13 of the apparatus 10.

[0198] It is then provided to repeat the method described above cyclically for each box 100 that enters the apparatus 10 through the inlet 12.

[0199] It is clear that modifications and / or additions of parts or steps may be made to the apparatus 10 and to the method as described heretofore, without thereby departing from the field and scope of the present invention, as defined by the claims.

[0200] It is also clear that, although the present invention has been described with reference to some specific examples, a person of skill in the art will be able to achieve other equivalent forms of apparatuses and methods for checking a box, having the characteristics as set forth in the claims and hence all coming within the field of protection defined thereby.

[0201] In the following claims, the sole purpose of the references in brackets is to facilitate their reading and they must not be considered as factors restricting the claims’ field of protection.

Claims

CLAIMS1. Apparatus (10) for checking a box (100) having at least a pair of top folding flaps (106, 107) for closing the box (100) and an internal compartment (110) containing one or several objects (200), said apparatus (10) comprising a conveyor (11) configured to move the box (100) on a supporting plane (P) along an advancement direction (A) through a closing station (30) and a taping station (50) configured to close the top flaps (106, 107) and then tape them, respectively, and a detection station (20) arranged upstream of the closing (30) and taping (50) stations and equipped with lateral sensors (22) configured to detect a lateral height (H) of said box (100), wherein said detection station (20) comprises upper sensors (25), for example distance sensors, arranged on a support bar (26) located above said box (100) at a predetermined fixed height (ZD) with respect to said supporting plane (P), characterized in that said upper sensors (25) are configured to detect a vertical distance (D) measured between said upper sensors (25) and said box (100), and by comprising a control and management unit (60) connected to said lateral sensors (22) and to said upper sensors (25), and comprising a data processing module (61) to calculate a difference (F) between said fixed height (ZD) and the vertical distance (D) detected by the upper sensors (25), and compare said lateral height (H) detected by the lateral sensors (22) with said calculated difference (F), wherein if said calculated difference (F) is equal to said lateral height (H), the control and management unit (60) deactivates said closing station (30) and said taping station (50) making said box (100) pass through said closing (30) and taping (50) stations without undergoing any closing and taping.

2. Apparatus (10) as in claim 1, characterized in that said detection station (20) further comprises additional sensors (23), configured to detect a position of said box (100) on said supporting plane (P) and a width (LW) of said box (100) perpendicularly to said advancement direction (A), and in that said control and management unit (60) is configured to selectively activate a sub-set of said plurality of upper sensors (25) which is aligned with and detects the box (100), based on the position and width (LW) of said box (100) detected by said additional sensors (23).

3. Apparatus (10) as in claim 2, characterized in that said additional sensors (23) are at least a pair of sensors facing each other on opposite sides with respect to theadvancement direction (A), and are configured to measure respective lateral distances (Yl, Y2) between each additional sensor (23) and a respective lateral wall (103, 104) of said box (100) that is closer to the sensor, and in that said control and management unit (60) is configured to selectively activate the sub-set of sensors of said plurality of upper sensors (25) located within a central space between said respective lateral distances (Yl, Y2).

4. Apparatus (10) as in claim 2 or 3, characterized in that if said calculated difference (F) is less than said lateral height (H), said processing module (61) is further configured to determine a first height (Hl), corresponding to the height of said box (100) in a closed configuration, through the formula Hl = H - LW / 2, where Hl is said first height, H is said measured lateral height and LW is said measured width, and in that the control and management unit (60) is configured to position said closing (30) and taping (50) stations at a height suitable for closing and taping at said first determined height (Hl).

5. Apparatus (10) as in any claim hereinbefore, characterized in that said vertical distance (D) detected by the upper sensors (25) is calculated as an average value of the vertical distances (D) detected by each sensor of said upper sensors (25).

6. Apparatus (10) as in any claim hereinbefore, characterized by comprising an inlet (12) and an outlet (13) between which the boxes (100) are advanced by means of the conveyor (11), and by comprising an abutment element (27), configured to temporarily block the advance of said box (100) when it reaches said detection station (20).

7. Apparatus (10) as in claim 6, characterized in that said abutment element (27) is selectively positioned between a lowered position, in which it is below said supporting plane (P) to allow the boxes (100) to transit, and a raised position, in which it protrudes above said supporting plane (P) to block the transit of the boxes (100).

8. Apparatus (10) as in any claim hereinbefore, characterized in that said lateral sensors (22) are an emitter and a receiver arranged on opposite sides with said box (100) therebetween.

9. Apparatus (10) as in any claim hereinbefore, characterized in that if said calculated difference (F) is less than said lateral height (H), the control and management unit (60) ascertains that said box (100) is open with the at least a pairof top folding flaps (106, 107) in a raised position, and commands said closing (30) and taping (50) stations to close and tape the at least a pair of top folding flaps (106, 107) of the box (100).

10. Apparatus (10) as in any claim hereinbefore, characterized by further comprising centering members (46) arranged in said closing station (30) and configured to move said box ( 100) into a reference position, along a transverse axis (Y) perpendicular to said advancement direction (A).

11. Apparatus ( 10) as in claim 10, characterized in that said centering members (46) comprise a plurality of rollers (47), preferably idle, configured to contact opposite lateral walls (103, 104) of said box (100) facilitating the advance of the box (100) in said advancement direction (A).

12. Method (10) for checking a box (100) having at least a pair of top folding flaps (106, 107) for closing the box (100) and an internal compartment (110) containing one or several objects (200), said method comprising the steps of:- providing a closing station (30) and a taping station (50) configured to close the top flaps (106, 107) and then tape them, respectively,- moving the box (100) on a supporting plane (P) along an advancement direction (A) through said closing (30) and taping (50) stations,- detecting a lateral height (H) of said box (100) by means of lateral sensors (22) arranged upstream of said closing (30) and taping (50) stations,- arranging upper sensors (25), for example distance sensors, on a support bar (26) located above said box (100) at a predetermined fixed height (ZD) with respect to said supporting plane (P), said method being characterized by further comprising the following steps:- detecting a vertical distance (D) measured between said upper sensors (25) and said box (100),- calculating a difference (F) between said fixed height (ZD) and said vertical distance (D) detected by said upper sensors (25),- comparing said lateral height (H) detected by said lateral sensors (22) with said calculated difference (F), wherein if said calculated difference (F) is equal to said lateral height (H), said box (100) is made to pass through said closing station (30) and said taping station (50) without undergoing any closing and taping by deactivating said closing (30) andtaping (50) stations.

13. Method as in claim 12, characterized by comprising a step of further detecting the position of said box (100) on said supporting plane (P) and a width (LW) of said box (100) perpendicularly to said advancement direction (A) by means of additional sensors (23), for example distance sensors, and selectively activating a sub-set of said upper sensors (25) which are aligned with and detect the box (100), based on the position and width (LW) of said box (100) detected by said additional sensors (23).

14. Method as in claim 12 or 13, characterized by comprising, if said calculated difference (F) is less than said lateral height (H), a step of determining a first height (Hl) of said box (100), corresponding to the height of said box (100) in a closed configuration, through the formula: Hl = H - LW / 2, where Hl is said first height, H is said measured lateral height, and LW is said measured width, and in that said closing (30) and taping (50) stations are positioned at a height suitable for closing and taping at said first determined height (Hl).

15. Method as in any claim from 12 to 14, characterized in that if said calculated difference (F) is less than said lateral height (H), said closing station (30) and said taping station (50) are commanded to close and tape the at least a pair of top folding flaps (106, 107) of the box (100).

16. Method as in any claim from 12 to 15, characterized in that the step of detecting the vertical distance (D) comprises calculating an average value of said vertical distances (D) detected by each sensor of said upper sensors (25).