Automated equipment for preparing coatings

Abstract

An automated device for preparing paint comprises: an automated storage station (24) configured to accommodate a plurality of closed containers (C', C") having different formats, an automated production line (26) comprising a plurality of operating stations, a robotic unit (60) movable between the stations of the automated production line (26) to pick up each container (C', C") in an entry station (42) and to transfer it continuously from one station to the next, the robotic unit (60) having an adjustable gripping member (72) configured to grip containers (C', C") having at least two different sizes, and a control unit (22) configured to receive a paint order, the paint order comprising information relating to the format of the container and the paint color requested by the buyer.

Description

Technical Field

[0001] The present invention relates generally to the production of coatings and the like, and to automated apparatus for preparing coatings.

[0002] More specifically, the invention relates to an apparatus in which a closed container pre-filled with a neutral base is opened to add a measured amount of dye, then re-closed, stirred to uniformly mix the dye and base, and finally labeled. Background Art

[0003] Paints and varnishes, whether for amateur or professional use, are typically sold by retail outlets, department stores, or distribution centers.

[0004] Typically, paint shops don't have every possible color and size in stock. Therefore, paint shops are often equipped with a tinting machine, which creates the paint the end user desires by adding pre-filled containers of dye with a neutral base (usually white or clear). The tinting machine controls the dosage of dye to achieve the desired color. After the dye is added, it must be mixed to achieve a uniform color.

[0005] Having the coating prepared on request can require a long wait for the buyer, especially for professional users who require medium to large quantities of product in a relatively short period of time.

[0006] Prior art systems for preparing paint have been proposed that allow for limiting waiting times for users at points of sale. US Pat. No. 6,959,284 discloses a paint preparation system in which a consumer orders paint from a supplier via the internet or a communication line. The customer's order information is entered into a computer and sent to a production line where paint of the color specified in the order is prepared. The production line uses standard-sized containers, which can be partially filled to obtain the amount of paint indicated in the order.

[0007] Customers purchasing paint at the point of sale often have varying needs depending on the container format. Automated equipment is typically configured to operate with a standard container format, and installation and operation are required to adapt the production line to different container formats. Consequently, automated systems are often unsuitable for producing small quantities of paint in a variety of container formats within a short timeframe. Summary of the Invention

[0008] The present invention aims to provide an automated device for preparing coatings that overcomes the problems of the prior art.

[0009] According to the invention, this object is achieved by an automation device having the features forming the subject matter of claim 1 .

[0010] The claims form an integral part of the disclosure provided herein regarding the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The invention will now be described in detail with reference to the accompanying drawings, given by way of non-limiting examples only, in which:

[0012] Figure 1 is a schematic diagram of an automated system for managing orders for coatings, etc.

[0013] Figure 2 is Figure 1 A side view of the automated storage station indicated by arrow II in FIG.

[0014] Figure 3 It is along Figure 2 The front view of arrow III,

[0015] Figure 4 yes Figure 1 A perspective view of the automated production line indicated by arrow IV.

[0016] Figure 5 is Figure 4 A side view of the entrance station indicated by arrow V,

[0017] Figure 6 and Figure 7 yes Figure 4 A side view and a plan view of a robot unit indicated by arrow VI in FIG. 1 , the robot unit being in a configuration for picking up and transporting containers of a first format, and

[0018] Figure 8 and Figure 9 yes Figure 6 and Figure 7 Side and plan views of a robotic unit in a configuration for picking up and transporting containers of a second format.

[0019] It should be understood that the different figures may not all be reproduced to the same scale and that some components may be removed in order to simplify the understanding of the figures. DETAILED DESCRIPTION

[0020] refer to Figure 1 Reference numeral 10 denotes a web platform for managing orders for paint, etc. Web platform 10 is configured to receive orders from a user U, for example, via the Internet. An ordinary user U can connect to web platform 10 via the Internet using a communication device such as a computer 12, a mobile phone, or a tablet computer 14. User U can place an order on web platform 10 by connecting to a website or using a dedicated application.

[0021] The order entered on the network platform 10 includes at least the following information:

[0022] The color of the paint to be purchased, identified by a code,

[0023] Container sizes can be selected from a number of pre-defined standard sizes.

[0024] the number of containers of the selected format with the required color of paint,

[0025] the order collection method (e.g. at the point of sale, home delivery, collection at a distribution centre, etc.),

[0026] Payment terms.

[0027] Orders entered on the web platform 10 may also contain information about the user's geographical location to allow the user to select the nearest point of purchase or collection.

[0028] Once a valid order is received, the network platform 10 sends the order to an automated device 20 configured to produce the coating. The network platform 10 can be connected to multiple automated systems 20 and can be configured to select a specific automated system 20 based on specific criteria (e.g., proximity to the location of the user U, availability of materials for preparing the order, order fulfillment time, etc.).

[0029] After selecting the device 20 to which the order is to be sent, the network platform 10 sends an order for preparing the coating 10 to the automated device 20. The order is received by the control unit 22 of the automated device 20. The control unit 22 controls and manages the various units of the device 20 to prepare the order based on the received specifications (color code, container format, number of containers, etc.).

[0030] The automation equipment 20 includes Figure 2 and Figure 3 The automated storage station 24 shown, and Figure 4 The automated production line 26 is shown.

[0031] Reference Figure 2 and Figure 3 The automated storage station 24 accommodates a plurality of containers C', C", which are pre-filled with neutral bases, such as white or transparent, and are closed by corresponding lids. The containers C', C" accommodated in the storage station 24 have at least two different formats. In the example shown, the containers C', C" have two formats: a small format (e.g., 5 liters) and a large format (e.g., 25 liters). It will be understood that the storage station 24 can be configured to accommodate containers with more than two standard formats.

[0032] The storage station 24 comprises a plurality of storage sections 28, 30 for receiving containers of different sizes. In the example shown, a first storage section 28 contains containers C' of a first format and a second storage section 30 contains containers C" of a second format.

[0033] The storage parts 28, 30 of the storage station 24 may include a roller conveyor 32 that is inclined toward an automated picking device 34. The containers C', C" are advanced along the roller conveyor 32 by gravity. The roller conveyor 32 may be provided with corresponding locking devices 36, such as electric drives, which allow the containers C', C" to be advanced individually toward the picking position. The automated picking device 34 includes a fixed frame 38 and a mobile platform 40, which receives individual containers C', C" from the roller conveyor 32. The mobile platform 40 of the automated picking device 34 is movable in a linear direction on three axes X, Y, and Z and is operated by the electronic control unit 22. Based on the request of the individual order to be completed, the platform 40 picks up the pre-filled container formats corresponding to the order and places them at the entrance station 42 ( Figure 4 and Figure 5 )middle.

[0034] Reference Figure 5 , the entry station 42 may include a conveyor belt 44 that transports individual containers C', C" horizontally from the automated storage station 24 to the automated production line 26. The entry station 42 includes a size verification station that may be equipped with sensors 46, 48 for checking the dimensions of the containers C', C". The sensors 46, 48 may check the diameter and height of the containers C', C". The signals of the sensors 46, 48 are sent to the control unit 22, which verifies that the container located in the entry station 42 corresponds to the order being executed.

[0035] Reference Figure 4 , the automated production line 26 comprises a drilling station 50, a dosing station 52, one or two mixing stations 54, a labeling station 56 and an export station 58. All these stations are automated stations that operate under the control of the control unit 22. The automated production line 26 can be implemented as described in detail in Italian patent application No. 10 20190000 21804 of the same applicant.

[0036] The apparatus 20 comprises a robotic unit 60 which is movable along a guide 62 which extends in a linear direction X in front of the automated production line 26 . The movement of the robotic unit 60 along the guide 62 can be controlled by a belt or chain drive driven by a motor 64 controlled by the electronic control unit 22 .

[0037] Reference Figure 6-9, the robot unit 60 includes a base 66, which is provided with a slider 68 that engages the fixed guide member 62 in a sliding manner. The robot unit 60 includes a support body 70, which can be vertically moved (Z axis) between a lowered position and a raised position relative to the base 66. The support body 70 carries a clamping member 72 for clamping the containers C', C". The clamping member 72 includes an upper base 74, which can be moved between a disengaged position and an engaged position in a transverse direction (Y axis) relative to the support body 70 and protrudes from the support body 70 in a horizontal direction. The upper base 74 carries a vertical guide column 76, along which a fork-shaped element 78 can be moved in the vertical direction Z in a raised position ( Figure 6 ) with one or more lowered positions ( Figure 8 ) between the fork-like element 78 and the container C' having the largest diameter. The fork-like element 78 has a U-shaped seat 80 configured to grip the container C' having the largest diameter. The fork-like member 78 is also provided with two gripping elements 82 that are movable horizontally in the direction X, which allows the fork-like member 78 to be adapted to containers C' having a diameter smaller than the largest diameter.

[0038] The adjustment movement of the fork-shaped member 78 is controlled by an electric actuator operating under the control of the electronic control unit 22. Based on the information from the sensors 46, 48 that detect the size of the container C each time located in the entry station 42, the electronic control unit 22 controls the automatic adjustment of the robot unit 60 to adjust the height of the fork-shaped member 78 according to the height of the container C', C" to be picked up and to adjust the distance between the gripping members 82 according to the diameter of the container C', C" to be picked up.

[0039] Figure 6-9 The gripping member 72 is shown as adjustable between only two container sizes C′, C″. However, it should be understood that, depending on the number of standard container formats available in the automated storage station 24 , the gripping member 72 may be adjustable between a higher number of gripping formats.

[0040] After the structure of the clamping member 72 is adapted to the format of the containers C', C", the clamping member 72 moves in the direction Y to insert the containers C', C". During the movement along the direction Y, the clamping elements 82 of the clamping member 72 engage with the annular grooves formed at the upper ends of the containers C', C". After engaging the containers, the support body 70 of the robot unit 60 is raised to lift the containers C', C" from the surface on which they are placed.

[0041] Adjusting the robotic unit 60 to adapt the gripping members to different container formats is performed fully automatically and allows the system 20 to be quickly adapted to the processing of any container format without requiring manual setup when switching from one container format to another.

[0042] Reference Figure 4 、 Figure 6 、 Figure 8 , the robotic unit 60 may include an end cap application assembly 84 located above the support body 70, the end cap application assembly 84 including one or more end cap rods 86 in which a plurality of end caps are vertically stacked. The end cap application assembly 84 also includes a positioning member and a guide device, the positioning member being arranged to pick up an end cap removed from one of the two rods and position it over the hole of the container, and the guide device being configured to apply the end cap to the hole of the lid.

[0043] The robotic unit 60 and the automated production line 26 operate as described in detail in the same applicant's Italian patent application No. 1020190000 21804. In summary, the robotic unit 60 picks up a container C at the entry station 42 and moves it successively from one operating station 50 to another of the automated production line 26 .

[0044] In the first step, the robotic unit 60, under the control of the electronic control unit 22, adjusts the gripping member 72 to the format of the container located in the entry station 42. The robotic unit 60 then picks up the container located in the entry station 42 and transports it to the drilling station 50, where a hole is formed in the container's lid. The robotic unit 60 then moves the container with the perforated lid to the dosing station 52, where the dye required to obtain the desired color of paint is added to the neutral base contained in container C through the hole formed in the container's lid. After the dosing operation, the robotic unit 60 applies end caps to the holes formed in the container's lid and transfers the container to one of the mixing stations 54. There, the container is picked up by two opposing plates and rotated to mix the dye into the base and achieve a uniform distribution of the dye. The mixing station automatically adjusts to the height of the container C under the control of the control unit 22. At the end of the mixing step, the robotic unit 60 picks up the container from the mixing station 54 and places it in the exit station 58 where the container is labeled by the labeling unit 56. The container C can then be sent to the palletizing unit where containers of the same order are packaged for dispatch or collection by the user.

[0045] The system 20 is capable of continuously processing containers of varying sizes, selected according to customer orders. Paints of different colors can be prepared and filled in containers of varying sizes in the same order. The robotic unit 60's automatic adaptation to varying container sizes allows the system 20 to operate with maximum flexibility, without wasting time changing container formats.

[0046] Of course, without prejudice to the principle of the invention, the details of construction and the embodiments may vary widely with respect to what is described and illustrated, without thus departing from the scope of the invention as defined by the appended claims.

Claims

1. An automated device for preparing a coating, comprising: An automated storage station (24) configured to accommodate a plurality of closed containers (C', C") prefilled with neutral bases, wherein the automated storage station (24) has at least two storage sections (28, 30) configured to receive containers (C', C") having different sizes, wherein the automated storage station (24) comprises an automatic picking device (34) configured to pick up the containers (C', C") in the storage sections (28, 30), Automated production line (26) comprising an entry station (42) including a size verification station, a drilling station (50) for forming holes in the lids of the containers (C', C"), a dosing station (52) for dosing dye through the holes in the lids of the containers, at least one stirring station (54) for stirring the containers (C', C), a labeling station (56) and an exit station (58), a robotic unit (60) capable of moving between stations of an automated production line (26) to pick up each container (C', C") in the entry station (42) and transfer it successively from one station to the next until the exit station (58), the robotic unit (60) having an adjustable gripping member (72) configured for gripping containers (C', C") of at least two different sizes, and A control unit (22) is configured to receive a paint order including information related to the size of the container and the color of the paint required by the buyer, wherein, after receiving the order, the control unit (22) controls the automatic picking device (34) to pick up consecutive pre-filled containers with a size corresponding to the input order from the storage station (24), and controls the robot unit (60) to make the gripping member (72) suitable for the size of the containers intermittently placed in the entry station (42).

2. The device according to claim 1, wherein The robotic unit (60) includes a base (66) and a support body (70), wherein the base (66) is slidably connected to a fixed guide member (62) parallel to the automated production line (26), and the support body (70) can be vertically moved between a lowered position and a raised position relative to the base (66) and carries a clamping member (72), which can be laterally moved between a retracted rest position and an extended position for engaging a container.

3. The device according to claim 2, wherein The gripping member (72) comprises a fork-like arrangement (78) which is movable in a vertical direction to adapt the gripping member (72) to the height of containers of different sizes.

4. The device according to claim 3, wherein The fork-like device (78) has a U-shaped seat (80) configured to engage a container having a maximum diameter and to carry two gripping elements (82) that are adjustable in the horizontal direction to adapt the seat (80) to pick up containers having a diameter smaller than the maximum diameter.

5. The device according to any one of claims 1 to 4, wherein: The entry station (42) is provided with sensors (46, 48) which transmit information about the size of the containers intermittently arranged in the entry station (42) to the control unit (22), and the control unit (22) controls the robot unit (60) based on the information provided by the sensors (46, 48) to adjust the gripping member (72) to a size corresponding to the size of the containers intermittently present in the entry station (42).

6. The device according to any one of claims 1 to 4, wherein: The robotic unit (60) carries an end cap application assembly (84) configured to apply an end cap to close an aperture formed in a lid of the container.

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