Packaging system for assembling a package

Abstract

The present invention relates to a packaging system (100), a system for assembling packages, a method for assembling packages and a machine for assembling packages. The packaging system comprises at least one main transport unit (104) and at least one movable closed loop transport unit (102), wherein the at least one movable closed loop transport unit (102) is moved in three dimensions relative to the at least one main transport unit (104) to provide the main transport unit (104) with packaging material components and / or to perform packaging process operations on packages in assembly present on the main transport unit (104). The at least one movable closed loop transport unit (102) comprises a plurality of tools (108) mounted on independently motion controlled thrusters (106) for providing packaging material components to packages in assembly and / or providing packaging operations to packages in assembly. Furthermore, the present invention provides a system, a method and a machine for assembling any other item.

Description

Technical Field

[0001] This invention generally relates to transport units and systems for assembling packaging. More specifically, the invention relates to closed-loop transport units and systems for performing packaging processes during transport, and packaging machines using these units and systems. Furthermore, the invention also provides systems, methods, and machines for assembling any other articles. Background Technology

[0002] Conveying systems play a vital role in manufacturing for moving parts and / or products from one place to another. Traditionally, small driven vehicles, drive tracks, or conveyors are used, with the conveyor running on an electric motor. These drive tracks enable the movement of pallets or containers carrying products to be moved from one place to another.

[0003] Especially in packaging assembly lines, linear motion drive tracks are used to move primary, secondary, or tertiary packages during assembly to perform packaging operations on them. To perform packaging operations on packages that are moving during assembly, one or more conventional methods are employed, such as manual packaging by an operator as the packages move along the employed linear drive track. Another conventional method involves a packaging mechanism along a main drive track, performing packaging operations on a fixed track, where the packages during assembly move linearly along the drive track and remain stationary whenever a packaging operation is required.

[0004] The aforementioned traditional methods lack one or more features. For example, manual packaging operations are inefficient and have low productivity. Other automated traditional methods cannot perform packaging operations during assembly in the transportation process.

[0005] Furthermore, products processed by these traditional systems are limited by the shape, weight, and other characteristics of the packaging to be processed.

[0006] Furthermore, traditional packaging systems must adapt their packaging tools to the type of product being packaged (such as its shape, size, and weight), making them packaging-specific. This further reduces productivity and product diversity.

[0007] To provide a solution for packaging operations on assembled packages during transport, WO2019007923A1 discloses a particularly flexible processing station for performing a work process on items transported by a conveying unit of a first conveying device. This invention achieves the movement of a processing unit to items using a conveying unit of a second conveying device in the form of a long-stator linear motor, and the movement of the conveying unit using a first conveying device in the form of a long-stator linear motor, wherein the movement of the conveying unit of the second conveying device in the overlapping area is synchronized with the movement of the conveying unit of the first conveying device at least at certain times, and the work process is performed on the items during the synchronization with the movement of the processing unit.

[0008] Then, these packaging systems still have to adapt their packaging tools to the type of product being packaged (such as its shape, size, and weight), making them packaging-specific. This further reduces productivity and product diversity.

[0009] Therefore, the first objective of this invention is to achieve packaging design freedom and “maximum flexibility” through programmable dynamic manufacturing processes that cover a very wide range of packaging and products, sizes, shapes, styles, components, and assembly sequences.

[0010] Another objective of this invention is to enable synchronized, highly flexible, wide-ranging, and fully customizable manufacturing operations during transportation.

[0011] Another object of the present invention is to provide a scheme-driven and / or dynamic packaging system that can realize one or more packaging components and packaging operations or manufacturing operations according to the type of product to be packaged or operated.

[0012] Another objective of this invention is to shift to “linear drive execution” to maximize packaging efficiency and flexibility.

[0013] Another object of the present invention is to provide a compact, adaptable, and integrated packaging machine that can be combined with digital solutions without requiring changes to packaging-specific components or tools.

[0014] Another object of the present invention includes strong support for tooling adaptability and optimizable, software-driven flexibility in an integrated packaging machine.

[0015] Another objective of this invention is to achieve maximum flexibility through a synchronized and adaptive manufacturing process in space-optimized and motion-controlled transport, enabling the efficient assembly of a very wide range of product and packaging types, shapes, styles, and assembly sequences.

[0016] Another object of the invention includes enabling an adaptive manufacturing process in transport, wherein an optimizable manufacturing process is arranged within a multi-modal, dynamic, and sequential production process along a straight-drive route for transporting the master package, along which primary products and packaging material components are loaded and secondary and / or tertiary packaging is assembled. This further largely eliminates limitations in packaging design, style, and operation, while in turn achieving high levels of packaging design freedom, operational range, production capacity, optimized performance, productivity, and cost-effectiveness.

[0017] One object of the present invention is to achieve “synchronized” and motion-controlled manufacturing operations that are performed around the bottom, sides, corners and top of the package when the package is loaded through a packaging / manufacturing system during a pitch-optimized transport process (variable pitch and speed), while also taking into account the in-vehicle integrated tooling operations in separate controlled packages transported along the main constant-speed linear drive.

[0018] Another object of the invention includes modular and programmable execution of the packaging machine with a wide range of dimensional adjustments (position, height, and width of the linear drive), the ability to perform a series of packaging tool operations, flexibility in the order of operations, and flexibility in the operation of these tool operations, which further enables a high degree of freedom in packaging design.

[0019] Another object of the present invention is to provide an unconventional, non-traditional packaging machine that is not limited by the packaging design options and styles offered by traditional commercial solutions. Summary of the Invention

[0020] In one aspect of the invention, a movable closed-loop transport unit is adapted to provide one or more packaging material components to a main transport unit and / or perform packaging process operations on a given package in assembly present on the main transport unit, characterized in that the movable closed-loop transport unit is three-dimensionally movable relative to the main transport unit.

[0021] In one aspect of the invention, the movable delivery unit includes a plurality of tools mounted on individually motion-controlled pushers, which provide one or more packaging material components to a given package being assembled and / or provide packaging process operations to the given package being assembled. A pusher may support only one tool, or it may support multiple tools. In the latter case, these tools may each be suited to perform different operations separately, simultaneously, or sequentially, depending on the desired operation. Alternatively, a tool may be supported by several pushers. In one particular case, individual movement of the pushers supporting a tool relative to each other may cause the tool to move relative to the package being assembled (e.g., hinge or retract).

[0022] In one aspect of the invention, the tools on the thruster are wirelessly controllable and / or wirelessly (preferably contactless, and even more preferably inductively) powered.

[0023] One aspect of the present invention provides a system comprising one or more three-dimensional movable closed-loop transport units and a main transport unit as described above.

[0024] In another aspect, a system may be provided comprising one or more assemblies of at least two three-dimensional movable closed-loop transport units and a main transport unit.

[0025] Another aspect of the invention provides a system comprising one or more movable closed-loop transport units and / or one or more assemblies of at least two movable closed-loop transport units as described above, and a main transport unit, and further comprising a control system that synchronizes the stepping speed and spacing of the tool with the transport of the package being assembled on the main transport unit.

[0026] In one aspect of the invention, the system includes one or more movable closed-loop transport units and / or an assembly combined with a main transport unit and a control system as described above, the control system enabling the tool's pace and spacing to be synchronized with the transport of the package being assembled on the main transport unit, and the system further includes a control system capable of controlling the three-dimensional movement of the movable closed-loop transport units relative to the package being assembled. The control system capable of controlling the three-dimensional movement may include pre-production control (i.e., scenario-driven control) of the three-dimensional movement relative to the package to be assembled and / or may also include dynamic control during production.

[0027] In one implementation, the main transport unit may include individually motion-controlled thrusters that support the packaging during assembly and / or support tools mounted on the thrusters.

[0028] In addition, the main transport unit can also be a closed loop or a virtual closed loop.

[0029] Another aspect of the invention provides a system as described above, wherein a main transport unit includes tools on a thruster for providing packaging process operations to the given package being assembled, and wherein a control unit is capable of controlling the three-dimensional movement of the closed-loop transport unit, the main transport unit and its corresponding tools on the thruster, to simultaneously provide one or more packaging material components to the given package being assembled and / or simultaneously provide packaging process operations to the given package being assembled.

[0030] In another aspect, the system includes multiple movable closed-loop transport units, and the control system is further capable of controlling the three-dimensional movement of the movable closed-loop transport units to simultaneously provide one or more packaging material components to the given package being assembled and / or simultaneously provide packaging process operations to the given package being assembled.

[0031] One aspect of the present invention provides a packaging machine for assembling packages, comprising one or more movable closed-loop transport units and / or an assembly of at least two movable closed-loop transport units as described above.

[0032] Another aspect of the present invention provides a packaging machine for assembling packaging, including the system described above.

[0033] It should be understood that the aforementioned systems and packaging machines may also include any type of intermittent or reciprocating tooling system along the main transport unit for static or single or group (quantity) batch processing.

[0034] In one aspect of the invention, a method for assembling packaging is provided, the method comprising the steps of: providing one or more packaging material components to a three-dimensional movable closed-loop transport unit; transporting the components to a main transport unit via the movable closed-loop transport unit; and moving the movable closed-loop transport unit in a three-dimensional manner relative to the main transport unit.

[0035] In another aspect of the invention, a method for assembling packaging is provided, the method comprising the steps of: providing a given package to be assembled onto a master transport unit; performing packaging process operations on the given package to be assembled via a movable closed-loop transport unit; and moving the closed-loop transport unit in a three-dimensional manner relative to the master transport unit.

[0036] In another aspect of the invention, in the above-described method for assembling packaging, the step of providing one or more packaging material components or performing packaging process operations includes: (i) supplying and / or assembling packaging material components, such as partitions, handles, panels, and lids; (ii) supplying and / or loading one or more primary articles into secondary packaging, or supplying and / or loading one or more secondary packages into tertiary packaging; (iii) moving one or more packaging components or a portion thereof in a given orientation; (iv) securing one or more packaging components to a given package being assembled; (v) rotating the package being assembled or the final assembled package; (vi) inspecting the package and / or coding the package; (vii) accelerating, decelerating, cutting, stretching, compressing, flattening, folding, erecting, gluing, decorating components of the package being assembled, and all combinations thereof.

[0037] In another aspect of the invention, a movable closed-loop transport unit is proposed, which is adapted to provide one or more article components to a main transport unit and / or perform process operations on a given article in assembly present on the main transport unit, characterized in that the movable closed-loop transport unit is three-dimensionally movable relative to the main transport unit.

[0038] In addition, a machine for assembling articles is provided, which includes at least this movable closed-loop transport unit.

[0039] It should be understood that all aspects and implementation methods, systems, machines and methods described throughout the text in the case of assembly packaging are equally applicable in the case of assembling any other articles (especially automotive parts, medical devices, toys and consumer electronics). Attached Figure Description

[0040] Figure 1 An exemplary environment is shown for a movable closed-loop transport unit that moves relative to a main transport unit according to one embodiment of the present invention.

[0041] Figure 2 An exemplary environment of an adaptive packaging system according to one embodiment of the present invention is shown, the adaptive packaging system comprising a plurality of movable closed-loop transport units that move relative to a main transport unit.

[0042] Figure 3 A section of an adaptive packaging system according to one embodiment of the invention is shown, illustrating a plurality of movable closed-loop transport units located around a main transport unit, these movable closed-loop transport units surrounding a portion of the main transport unit in three dimensions.

[0043] Figure 4 A schematic plan view of a packaging system according to one embodiment of the present invention is shown. Detailed Implementation

[0044] The present invention provides a packaging system, packaging method and packaging machine for assembling packaging, comprising providing one or more packaging material components and providing packaging process operations for a given package in assembly.

[0045] In one aspect of the invention, the packaging system includes at least one main transport unit and at least one movable closed-loop transport unit, wherein the at least one movable closed-loop transport unit is movable relative to the at least one main transport unit in multiple degrees of freedom. In another aspect of the invention, the at least one movable closed-loop transport unit is movable in three dimensions relative to the at least one main transport unit to provide packaging material components to the main transport unit and / or perform packaging process operations on the package being assembled on the main transport unit. In one embodiment, the at least one movable closed-loop transport unit is capable of moving in three dimensions relative to the at least one main transport unit. The movable closed-loop transport unit is capable of moving along a vertical axis (Z) (e.g., with variable height relative to the main transport unit), along a horizontal axis (X) (e.g., with variable position in a direction parallel to the machine direction of the main transport unit), and along a second horizontal axis (Y) (e.g., with variable position in a direction perpendicular to the machine direction of the main transport unit).

[0046] In another embodiment, at least one movable closed-loop transport unit is also capable of tilting or swaying or rotating (commonly referred to as pitch, yaw, and roll) around one or more of the X, Y, and Z axes, and can perform these actions in any combination.

[0047] In cases where certain types of packaging assemblies do not require a movable closed-loop transport unit, or where maintenance or repair is required, three-dimensional movement may also include docking.

[0048] It will be apparent to those skilled in the art that the “closed-loop” transport unit in this packaging system includes not only linear drives (or so-called linear motors), but also all types of closed-loop transport systems or virtual closed-loop systems, thereby enabling individual motion control of its propellers in a closed or virtual closed loop.

[0049] Furthermore, the three-dimensional movable closed-loop transport unit may include a movement system for moving relative to the main transport unit. This movement system may include any type of movement system that enables the aforementioned three-dimensional movement, such as guide rails, tracks, slides, linear motors, robots, overhead frames, or overhead robots, either independently or integrated with the main transport unit or integrated into the packaging system frame or packaging machine frame.

[0050] In one aspect, the present invention provides a system comprising one or more such three-dimensional movable closed-loop transport units and a main transport unit. These movable closed-loop transport units may be positioned continuously relative to the main transport unit (i.e., positioned one after another along the main transport unit), or may be positioned parallel to each other (i.e., positioned at least on both sides of the main transport unit in a direction perpendicular to the machine direction), thereby surrounding the same portion of the main transport unit from at least both sides, or any combination of continuous and parallel positioning may be used.

[0051] exist Figure 3 In one embodiment shown, the packaging system may include an assembly of at least two movable closed-loop transport units located around the same portion of a main transport unit and surrounding said portion of the main transport unit at more than one side (e.g., three movable closed-loop transport units surrounding a portion of the main transport unit on the top, left, and right sides). In this configuration, at least one (preferably more than one, most preferably all) movable transport units are capable of moving independently of each other and relative to the main transport unit in three dimensions. In a preferred embodiment, more than one movable closed-loop transport unit surrounding a portion of the main transport unit is capable of moving individually or simultaneously along a vertical axis (Z) (e.g., with variable height relative to the main transport unit), along a horizontal axis (X) (e.g., with variable position in a direction parallel to the machine direction of the main transport unit), and along a second horizontal axis (Y) (e.g., with variable position in a direction perpendicular to the machine direction of the main transport unit). In addition, at least two movable closed-loop transport units surrounding the main transport unit can tilt or yaw individually or simultaneously, or rotate (commonly referred to as pitch, yaw, and roll) around one or more of the X, Y, and Z axes, and can perform these actions in any combination.

[0052] In other embodiments of the invention, the packaging system may further include at least three movable transport units that surround the main transport unit from at least three sides, are tilted toward the main transport unit at any suitable angle, are located at any suitable distance from the main transport unit, and move independently in three dimensions relative to the main transport unit, thereby covering movement around the main transport unit with maximum freedom. In this way, without departing from the meaning and scope of the invention, the packaging system is given great flexibility when operating on the packaging transported on the main transport unit.

[0053] Preferably, the tools on the pushers of the movable closed-loop transport unit and preferably the main transport unit are contactless (preferably inductively) powered. Furthermore, these tools can be wirelessly controlled via a remote control unit or control system.

[0054] A movable closed-loop transport unit includes a thruster on which a plurality of tools are mounted, wherein the thruster is coupled to the movable closed-loop transport unit. In one embodiment of the invention, the thruster is magnetically coupled to the movable closed-loop transport unit in a non-contact manner. In this embodiment, the movable closed-loop transport unit may have an electric coil, and the thruster may be equipped with a permanent magnet for generating an electromagnetic field between the movable closed-loop transport unit and the thruster. In one embodiment, the movable closed-loop transport unit may be implemented using an inductive cable, from which induced power is transmitted to the tools via the thruster.

[0055] At least one tool is coupled to a propeller for handling packaging material components. The tool is also inductively powered via the propeller. These tools supply packaging material components to the package being assembled and perform packaging process operations on the package as it is transported to the main transport unit. Because the movable closed-loop transport unit is inductively controlled, an electromagnetic force is generated by the power coils equipped with the movable transport unit. Therefore, under the influence of the electromagnetic force generated by the electromagnetic coils in the movable closed-loop transport unit and the permanent magnets in the propeller, the propeller moves freely above the movable closed-loop transport unit in a flight motion.

[0056] The linear actuators for both the movable closed-loop transport unit and the main transport unit are implemented using linear drive motors, which can also be remotely controlled. Furthermore, the control system controls the movement of the movable closed-loop transport unit around the main transport unit. For example, the control system controls the three-dimensional movement of the movable closed-loop transport unit relative to the main transport unit.

[0057] Furthermore, the operation of the thrusters and tools can be remotely controlled. In one implementation, one or more wireless communication protocols can be implemented for remote control of the thrusters and tools, such as, but not limited to, short-range wireless communication (e.g., Bluetooth, infrared, WLAN, WAN, or Internet Protocol).

[0058] In one aspect of the invention, the packaging system, the packaging method, and the packaging machine can also be implemented in a series of manufacturing operations (such as tool handling or tooling operations on material components).

[0059] Without departing from the meaning and scope of the invention, throughout the disclosure, the movable closed-loop transport unit may also be referred to as a "movable transport unit", and the main transport unit may also be referred to as a "main transport unit".

[0060] Figure 1 An exemplary environment of a movable closed-loop transport unit that moves relative to a main transport unit according to an embodiment of the present invention is shown. The adaptive packaging system 100 includes a movable closed-loop transport unit 102 (referred to as "movable transport unit" 102), a main transport unit 104 (referred to as "main transport unit" 104), and a central computer 112, wherein the movable closed-loop transport unit 102 is capable of moving relative to the main transport unit 104 in three dimensions (X, Y, Z directions).

[0061] At least one tool is coupled to a thruster for handling packaging material components. The tool is also inductively powered via the thruster. These tools supply packaging material components to the package being assembled and perform packaging process operations on the package as it is transported to the main transport unit. Because the movable closed-loop transport unit is inductively controlled, an electromagnetic force is generated by the power coils of the movable transport unit. Therefore, under the influence of the electromagnetic force generated by the electromagnetic coils in the movable closed-loop transport unit and the permanent magnets in the thruster, the thruster moves freely above the movable closed-loop transport unit in a flight motion. When the thruster moves in a non-contact manner, the mounted tool is also inductively powered via the thruster and begins to move when mounted on the thruster.

[0062] The drive systems for the movable closed-loop transport unit and the main transport unit may include linear motors. Furthermore, the control system controls the movement of the movable closed-loop transport unit around the main transport unit. For example, the control system controls the three-dimensional movement of the movable closed-loop transport unit relative to the main transport unit.

[0063] Furthermore, the operation of the thrusters and tools can be remotely controlled. In one implementation, one or more wireless communication protocols can be implemented for remote control of the thrusters and tools, such as, but not limited to, short-range wireless communication (e.g., Bluetooth, infrared, WLAN, WAN, or Internet Protocol).

[0064] In one aspect of the invention, the packaging system, the packaging method, and the packaging machine can also be implemented in a series of manufacturing operations (such as tool handling or tooling operations on material components).

[0065] Without departing from the meaning and scope of the invention, throughout the disclosure, the movable closed-loop transport unit may also be referred to as a "movable transport unit", and the main transport unit may also be referred to as a "main transport unit".

[0066] Figure 1 An exemplary environment of a movable closed-loop transport unit that moves relative to a main transport unit according to an embodiment of the present invention is shown. The adaptive packaging system 100 or the adaptive packaging system 100 includes a movable closed-loop transport unit 102, a main transport unit 104, and a central computer 112, wherein the movable closed-loop transport unit 102 is capable of moving relative to the main transport unit 104 in three dimensions (X, Y, Z directions).

[0067] Both units preferably have a linear driver driven by a linear drive motor. Figure 1A highly integrated single transport unit (102, 104) is shown that can be flexibly used for layout configuration. Multiple movable transport units 102 and multiple main transport units 104 can be integrated together to form a layout of linear drive rails or linear actuators.

[0068] The movable closed-loop transport unit 102 provides packaging material components to the main transport unit 104 for performing packaging operations on the packages transported to the main transport unit 104. The packaging material components provided by the movable closed-loop transport unit 102 may include, but are not limited to, primary packaging (e.g., bottles, cans, barrels, etc.) or components thereof (e.g., caps, lids, labels, etc.), secondary packaging (e.g., boxes, cartons, crates, etc.) and components thereof (e.g., collapsible packaging blanks, handle assemblies, partitions, reinforcements, straps, etc.), or tertiary packaging (e.g., pallets, etc.) or components thereof (e.g., foil sheets, etc.). Furthermore, the packaging being assembled on the main transport unit 104 may include primary packaging (e.g., bottles, cans, barrels, etc.), secondary packaging (e.g., boxes, cartons, crates, etc.), or tertiary packaging (e.g., pallets, etc.).

[0069] The mobile transport unit 102 is highly integrated and can be flexibly used in various layout configurations. Multiple mobile transport units 102 can be integrated together to form a mobile drive track. A mobile transport unit 102 includes a thruster 106, a tool 108, a sensor unit for detecting the position of the thruster 106 or the tool 108 mounted thereon, and a flat coil for generating a traveling magnetic field for the thruster 106 and / or the tool 108 to travel thereon. The mobile transport unit 102 is also capable of communicating with a central computing device 112 or a control system 112 via a communication channel 110. The central computing device 112 controls the three-dimensional movement of the mobile transport unit 102 relative to the main transport unit 104. The central computing system 112 is also capable of controlling the three-dimensional movement of the mobile transport unit 102 to simultaneously provide one or more packaging material components to a given package being assembled and / or simultaneously perform packaging process operations on the given package being assembled.

[0070] The thruster 106, mounted above the movable transport unit 102, moves without contact above the movable transport unit 102 under the action of electromagnetic force. The thruster 106, tool 108, and movable transport unit 102 are inductively powered.

[0071] The central computing device 112 can be a local or remote control unit for controlling the operation of the mobile transport unit 102, the thruster 106, and the tool 108 mounted thereon. In an embodiment of wireless operation control of the thruster 106 and the tool 108, the thruster 106 is equipped with an antenna for wireless communication via a wireless communication link (such as WLAN or WAN). Each mobile transport unit 102 and tool 108 of the thruster 106 can form a dedicated wireless network in which the thruster 106, the tool 108, and the mobile transport unit 102 can be wirelessly controlled via data transmission cables following a closed loop or virtual closed loop. Furthermore, in one embodiment, the tools 108 can be individually wirelessly controlled within their own dedicated wireless network.

[0072] The central computing device 112 can be any computing device, including but not limited to desktop computers, laptops, smartphones, mobile phones, information boards, tablets, phablets, etc.

[0073] The mobile transport unit 102 communicates bidirectionally with the central computing device 112 via a communication channel 110 (e.g., a communication fieldbus 110). The central computing device 112 is equipped with a software application 114 that monitors, controls, and optimizes the operation of the entire packaging system 100 (including the mobile transport unit 102, the main transport unit 104, the pusher 106, and the tool 108).

[0074] Software application 114 can analyze the positioning measurements of pusher 106 and tool 108 and provide computing device 112 with optimized paths, or positioning, or trajectory management functions for the entire packaging system 100 (including movable transport unit 102, main transport unit 104, pusher 106, and tool 108) to further monitor and control the position and movement of pusher 106 and tool 108 above movable transport unit 102. Computing device 112 is also capable of synchronizing the step speed and spacing of tool 108 with the transport step speed and spacing of the package being assembled on main transport unit 104.

[0075] The main transport unit 104 provides the packaging under assembly during transport. As the movable transport unit 102 moves in three dimensions along / around the main transport unit 104, the packaging is operated on by packaging material components provided by the propeller 106 and tool 108 of the movable transport unit 102.

[0076] Furthermore, the main transport unit 104 also communicates bidirectionally with the computing device 112 in the same manner as the mobile transport unit 102 communicates with the computing device 112. Similar to the mobile transport unit 102, the main transport unit 104 is controlled by the computing device 112 via wired or wireless protocols. The application 114 can provide the computing device 112 with optimized path, positioning, or trajectory management functions for packages moving above the main transport unit 104 and / or the main transport unit 104 itself, to further monitor and control the position and movement of packages above the main transport unit 104.

[0077] In one embodiment of the invention, the main transport unit 104 may further include one or more thrusters (similar to or different from thruster 106) and one or more tools (similar to or different from tool 108) mounted above the thrusters. The thrusters of the main transport unit 104 can provide packaging process operations to a given package being assembled, and the central computing device 112 controls the three-dimensional movement of the movable transport unit 102 and controls the movement of the main transport unit 104 and its corresponding tools on the thrusters to simultaneously provide one or more packaging material components to the given package being assembled and / or simultaneously provide packaging process operations to the given package being assembled.

[0078] In one embodiment of the invention, the linear actuator of the movable transport unit 102 is parallel to the linear actuator of the main transport unit 104, and it can act as the main unit of the packaging system 100. In another embodiment of the invention, the linear actuator of the movable transport unit 102 can be tilted at a certain angle relative to the linear actuator of the main transport unit 104; for example, the movable transport unit 102 can be tilted or inclined at a certain angle relative to the main transport unit 104. In yet another embodiment, the movable transport unit 102 can be located at any suitable distance from the main transport unit 104.

[0079] For example, in order to dynamically assemble secondary packaging (during transportation), packaging system 100 can perform the following process steps:

[0080] (a) Supplying carton blanks on the main conveying unit 104

[0081] I. Pre-supply of cardboard boxes

[0082] II. Cardboard boxes and containers

[0083] III. Outbound carton processing (picking, aligning, stacking, transferring to main linear drive vehicle, delivery);

[0084] (b) Supplying primary products on the mobile delivery unit 102

[0085] I. Pre-supply of primary products

[0086] II. Primary product picking (position and orientation scanning, dynamic picking, orientation, grouping, setting spacing, and transfer to intermediate pad conveyor)

[0087] III. Primary product grouping (sorting, grouping, picking, and dynamic transfer, as well as delivery to the bottom plate of the carton blanks transported to the main transport unit 104 or the main transfer system vehicle);

[0088] (c)24 Packaging handle reinforcement

[0089] (d) Laser cutting

[0090] (e) Apply installation adhesive

[0091] (f) Forming a U-shape

[0092] (g) Partition supply

[0093] I. Pre-supply of partitions

[0094] II. Partitioned material box

[0095] III. Baffle outbound (picking, installation, forming, transfer, and insertion);

[0096] (h) Handle supply

[0097] I. Handle pre-supply,

[0098] II. Handle material box,

[0099] III. Handles out of the warehouse (picking, installation, forming, transfer, and insertion);

[0100] (i) Carton assembly (sealing)

[0101] (j) Filling and Packaging Inspection

[0102] (k) Apply sealant 1 & 2

[0103] (l) Carton sealing

[0104] (m) Packaging rotation (basket) [optional]

[0105] (n) Packaging tape supply [optional]

[0106] I. Packing tape pre-supply,

[0107] II. Packaging with material box,

[0108] III. Packing tape outbound (picking, forming, transfer, and application);

[0109] (o) Finished product packaging inspection

[0110] (p) Carton Code

[0111] (q) Packaging grouping [optional] or packaging discharge

[0112] Figure 2 An exemplary environment of an adaptive packaging system according to an embodiment of the present invention is shown, the adaptive packaging system including a plurality of movable transport units 102 movable relative to a main transport unit 104. The adaptive packaging system 100 includes a plurality of movable transport units 102 and a main transport unit 104. The movable transport units may be supported by a base machine frame above the main transport unit 104.

[0113] A highly adaptable programmable dynamic manufacturing platform (such as an adaptive packaging system 100) includes modules of multiple movable closed-loop transport units 102, which can be positioned in three dimensions and operate in the opposite direction to the main transport unit 104. In one embodiment, the three-dimensional movement of the movable transport units 102 may include, but is not limited to, movement along a vertical axis (e.g., along a height starting from the package being transported on the main transport unit 104) and along two horizontal axes (e.g., relative to the position and width of the package being transported on the main transport unit 104).

[0114] The modules of the movable closed-loop transport unit 102, which can be positioned in three dimensions, operate in the opposite direction to the linear actuator of the main transport unit 104. All independently positioned and motion-controlled actuators 106 supporting and transporting the movable transport unit 102 in controlled synchronous motion are contactlessly powered and synchronized, and are also wirelessly (unrestricted) automatically controlled. The actuators 106 have custom tools 108 and / or associated tooling processes that act on and around the package being assembled while performing the same controlled synchronous motion transport on the main transport unit 104.

[0115] The adaptive packaging system 100 includes multiple modules of a programmable robot customization tool (108) mounted on one or more motion-controlled thrusters (106) of a position-adjustable linear actuator of a mobile transport unit 102. The mobile transport unit 102 is configured and optimally controlled to handle and assemble packages while following the motion trajectory of a main transport unit 104, and thus travels with the packages being assembled at the main transport unit 104.

[0116] As described above, the module of tool 108, mounted above the pusher 106 of the movable transport unit 102, can move in three dimensions relative to the linear drive of the main transport unit 104. This further means that the position of each movable transport unit 102 or module 102 can be adjusted relative to the position of the package being transported on the main transport unit 104 and relative to the linear drive of the main transport unit 104. The positional adjustability features of the tool 108 mounted on the linear drive, the pusher 106, and the movable transport unit 102 include positional adjustments in three dimensions, such as positional adjustments along the vertical height above the carton support platform being transported on the main transport unit 104, as well as positional adjustments along the width between the tracks of the movable transport unit 102 and the main transport unit 104, and positional adjustments along the absolute horizontal position (in the machine direction) relative to the reference plane of the main transport unit. These positional adjustability features of the movable transport unit 102 provide a range of machine dimensions that, when combined with compatible pushers 106 and tools 108, can be adapted to and optimally produce a wide range of package sizes and styles.

[0117] The adaptive packaging system 100 is a fusion of various technologies that provide various functions for the adaptive packaging system 100. For example, the adaptive packaging system 100 includes a main transport unit 104 that transports individual packages on a transport linear drive and has a step speed setting feature. The adaptive packaging system 100 further includes modules or units of multiple position-adjustable "manufacturing process" linear drives, which are movable transport units 102. In addition, the adaptive packaging system 100 also includes thrusters 106, wherein the movement trajectory of the thruster 106 of each movable transport unit 102 is synchronized with the movement trajectory of the main transport unit 104.

[0118] The adaptive packaging system 100 further includes a contactless (unrestricted) inductive power supply to the thruster 106. Additionally, the adaptive packaging system 100 enables wireless (unrestricted) automated control communication with the thruster 106 via a central computing system 112. The adaptive packaging system 100 also includes separately controlled in-vehicle tooling operations for packaging transport along the main transport unit 104.

[0119] Therefore, through the integration of various technologies in the main transport unit 104, the movable transport unit 102, and their thrusters 106 and tools 108, “synchronous,” unrestricted, and motion-controlled manufacturing operations are achieved using the thrusters 106 and the mounted tools 108. These thrusters and tools operate around the bottom, sides, corners, and top of the package as it is transported on the main transport unit 104 via the adaptive packaging system 100 in a spacing-optimized manner (variable spacing and speed). Thus, the adaptive packaging system 100 features synchronized and motion-controlled manufacturing operations performed by the thrusters 106 and tools 108 of the movable transport unit 102, all of which take place around the package during transport, wherein the package itself being transported on the main transport unit 104 is being transported in a motion-controlled manner (i.e., speed and spacing are not constant).

[0120] This highly programmable adaptive packaging system 100 (where stroke, motion trajectory, cam, spacing, and sequence are all programmable) can perform optimized packaging operations for a very wide range of packaging styles (width, length, and height), shapes, forms, and formats. Combined with tooling (such as tool 108) interchangeability and related software, this further expands the functionality of the manufacturing platform (such as the adaptive packaging system 100).

[0121] Each device or component in the adaptive packaging system 100 is controlled or automated by a central computing system 112 via a software application 114 that controls the operation of the adaptive packaging system 100. The automation software application 114 controls the synchronized movement and controlled motion of all devices in the adaptive packaging system 100. In one embodiment, the adaptive packaging system 100 includes automatic switching of pusher and tool sets for various packaging styles, meaning that no changes to components (e.g., pushers and tools) are required for a specific package. Automatic switching is controlled by the automation software application 114.

[0122] In one embodiment, the adaptive packaging system 100 includes automated (or semi-automated) docking of subassembly assemblies or complete AGV (Automated Guided Vehicle) guiding modules controlled by an automation software application 114. In this embodiment, the adaptive packaging system 100 may include the swapping of integral modules of movable transport units 102 around the main transport system (204) loop, not just the swapping of pushers 106 and tools 108. These modules may be mobile AGV units that can be summoned to the system 100 from remote locations (e.g., parking locations) to automatically locate, dock, connect, and integrate them into a safety system for synchronized automated control. The reverse procedure is applied upon separation. Such a system, combined with dockable assemblies (e.g., the adaptive packaging system 100), significantly reduces limitations associated with the type of configuration initially ordered for the packaging machine, making it more adaptable, versatile, and less prone to obsolescence.

[0123] In one embodiment, machine 200 may include a linear drive track 202 comprising a plurality of movable transport units 102 that move and operate in three dimensions around the linear drive track 204, which includes a plurality of main transport units 104. In another embodiment, machine 200 may include more than one linear drive track (e.g., linear drive track 202), each linear drive track comprising a plurality of movable transport units 102 that move and operate in three dimensions around the linear drive track 204, which includes a plurality of main transport units 104.

[0124] In one implementation, all software-controlled devices in the adaptive packaging system 100 can be reprogrammed and swapped or upgraded to adapt to a large series (category) of products being produced, thereby ensuring that the adaptive packaging system 100 remains relevant and suitable for optimizing production.

[0125] By switching to whole-machine linear drive execution instead of the linear drive in traditional machines, the Adaptive Packaging System 100 improves performance, range, flexibility, adaptability, and productivity.

[0126] The linear drive thruster 106 and / or tool (108) are custom-processed and powered and controlled without being connected to the host (e.g., the linear drive of the movable transport unit 102 or the main transport unit 104) by pneumatic, electric or mechanical means, because the thruster 106 is non-contactly coupled to the movable transport unit 102 under electromagnetic force.

[0127] Figure 3A segment of an adaptive packaging system according to an embodiment of the present invention is shown, illustrating a plurality of movable closed-loop transport units surrounding a main transport unit (the main transport unit of the adaptive packaging system) in three dimensions. Segment 300 of the transport system 100 includes three movable transport units 102 surrounding a main transport unit 104, these movable transport units surrounding the main transport unit 104 from three sides (e.g., top, left, and right). The main transport unit 104 can act as the host of the transport system 100, and packages being transported on the main transport unit 104 move in a machine direction as indicated by arrow 302.

[0128] Each of the three movable transport units 102 is capable of moving independently of each other in three dimensions. In other words, the three movable transport units 102 are capable of moving relative to the main transport unit 104 in three dimensions or in the directions of the three axes (X-axis, Y-axis, and Z-axis). Optionally, the three movable transport units 102 may also move in the machine direction 302, or in the direction opposite to the machine direction 302. Alternatively, in one embodiment, without departing from the meaning and scope of the invention, one or two of the three movable transport units 102 may move in the machine direction 302, while the remaining movable transport units 102 may move in the direction opposite to the machine direction 302, depending on the requirements and design of the transport system 100.

[0129] It will be apparent to those skilled in the art that, without departing from the meaning and scope of the invention, the packaging system may further include at least three movable transport units 102 that surround the main transport unit 104 from at least three sides, are tilted toward the main transport unit 104 at any suitable angle, are located at any suitable distance from the main transport unit 104, and move independently in three dimensions relative to the main transport unit 104, thereby covering movement around the main transport unit 104 with maximum freedom and giving the transport system 100 great flexibility when performing operations on the packaging transported on the main transport unit 104.

[0130] Therefore, by including any suitable number of movable transport units 102 around the main transport unit 104, the adaptive packaging system 100 possesses high flexibility and dynamism, wherein the movable transport units 102 are capable of moving independently relative to the main transport unit 104 in three dimensions and are capable of being positioned at any suitable distance and at any suitable tilted, parallel, or non-parallel (at rotational angles) relative to the main transport unit 104 in any direction. Thus, the movable transport units 102 are capable of providing packaging components and packaging operations to the packaging transported on the main transport unit 104 with multiple degrees of freedom of motion.

[0131] Figure 4 A schematic plan view of a transport system 100 according to an embodiment of the present invention is shown. The schematic plan view 400 illustrates the transport system 100, which includes a main transport unit 104 and a plurality of movable transport units 102. The main transport unit 104 can act as the host of the transport system 100, and the plurality of movable transport units 102 can move in three dimensions relative to the main transport unit 104. Furthermore, as... Figure 4 As shown, multiple movable transport units 102 are positioned at different angles or locations relative to the main transport unit 104, and their positions can be set with six degrees of freedom, enabling the movable transport units 102 to perform packaging operations in multiple degrees of freedom in three dimensions at the location of the packages being transported on the main transport unit 104. Therefore, the transport system 100 can achieve maximum flexibility and dynamism when providing packaging operations to the packages being transported on the main transport unit 104.

[0132] In one embodiment of the invention, the linear actuator of the movable transport unit 102 is parallel to the linear actuator of the main transport unit 104, which may be the host unit of the transport system 100. In another embodiment of the invention, the linear actuator of the movable transport unit 102 may be tilted at a certain angle relative to the linear actuator of the main transport unit 104. For example, the movable transport system 102 may be tilted or inclined at a certain angle relative to the main transport system 104. In yet another embodiment, the movable transport unit 102 may be located at any suitable distance from the main transport unit 104.

[0133] The packaging system can be at least partially embedded in a supporting frame structure, wherein one or more of the main transport unit 104 and / or multiple movable transport units 102 are supported on the frame structure.

[0134] The linear drives of the main transport unit 104 and the movable transport unit 102 may also have their own movement systems, allowing them to be mounted on movement systems (such as, but not limited to, guide rails, actuators, motors, or slide rails). These movement systems of the movable transport unit 102 and the optional main transport unit 104 are supported on a frame structure.

[0135] In one implementation, for protection and support, the entire packaging system is installed together with the frame structure, wherein the linear actuator's moving system (e.g., a slide rail) is integrated with the frame structure and the moving system can move on the frame structure.

[0136] In another aspect of the invention, a method for assembling packaging includes the steps of providing one or more packaging material components to a three-dimensional movable closed-loop transport unit 102; and the steps of transporting the packaging components to a main transport unit 104 via the movable closed-loop transport unit 102 for performing packaging process operations on the packaging being transported on the main transport unit 104, wherein the movable closed-loop transport unit 102 moves in a three-dimensional manner relative to the main transport unit 104.

[0137] In one implementation, the steps of providing one or more packaging material components or performing packaging process operations include: (i) supplying and / or assembling packaging material components, such as partitions, handles, panels, and lids; (ii) supplying and / or loading one or more primary articles into secondary packaging; (iii) moving one or more packaging components or a portion thereof in a given orientation; (iv) securing one or more packaging components to a given package being assembled; (v) rotating the package being assembled or the final assembled package; and (vi) inspecting the package and / or coding the package, and these operations can be combined in any way.

[0138] Advantageously, the system of the present invention provides an integrated fusion of linear motors, inductive power supplies, wireless machine automation, robots, and custom tooling assemblies. The necessary combination enables packaging design freedom and "maximum flexibility" through a programmable dynamic manufacturing process (secondary packaging assembly during transport). This programmable dynamic manufacturing process covers a very wide range of packaging and products, sizes, shapes, styles, components, and assembly sequences without the need to replace packaging-specific components (e.g., pushers and tools), thereby increasing productivity and promoting product diversity.

[0139] This invention provides an integration of independent three-dimensional mobile transport units, customized robots, wireless machine automation, and contactless power sources to maximize synchronous, highly flexible, and wide-ranging customized production operations during transportation.

[0140] Furthermore, the present invention provides the overall architecture of the packaging machine, which is a compact adaptive packaging system with digital solutions, while eliminating the need for replacement parts (e.g., pushers and tools), and strongly supports tool adaptability and optimizable, software-driven flexibility.

[0141] A key enabling factor of this invention is the implementation of an adaptive manufacturing process during transport. This optimizable manufacturing process is arranged within a multi-module, dynamically sequential production process along a straight-drive route of the main packaging conveyor, along which primary products and packaging material components are loaded and the packaging is assembled. This largely eliminates limitations in packaging design, form, and operation, while in turn achieving superior packaging design freedom, operational range, production capacity, optimized performance, productivity, and cost-effectiveness.

[0142] Furthermore, because the system of the present invention is inherently highly modular, this modular architecture of the packaging machine facilitates easy selection of content and layout during ordering. Due to the ease of content and layout selection, various movable modules can be freely included or excluded, from which arbitrary selection can be made to move around the linear drive loop of the main conveyor system. Moreover, the ease of content and layout selection also allows for the selection of equally suitable module sizes, and the easy selection of the module's direction of movement around the main conveyor system (clockwise or counterclockwise), feeding direction (from left or right), and the direction of the discharging module (left, right, or front), as well as other options that can be easily selected in the layout configuration of the present invention.

[0143] A further advantage of this system is that, by avoiding the fixed manufacturing operations of multiple conventional machines performing a limited range of products, and considering the feed and discharge conveyor network system, entrance islands, packaging material movement, waste removal paths, and multi-personnel spaces, the total footprint of a single larger machine is smaller compared to a network of smaller conventional machines. This results in significantly higher production density and better utilization of capacity (the height of the packaging hall). In addition to the above, a single machine not only occupies a smaller area but also supports a wider range of different product and packaging configurations in a more updatable, flexible, scalable, and adaptable manner compared to what is practically achievable with a series of conventional machines.

[0144] Furthermore, the aforementioned "range" is achieved without requiring changes to components (e.g., pushers and tools), while maintaining automatic switching of programmable and software-controlled devices. Therefore, switching can be completed within minutes, significantly reducing non-productive changeover time and thus improving productivity. Through the aforementioned automation and digitalization solutions, rapid and coordinated changeovers are also possible, making the impact of packaging line changeovers on productivity virtually negligible.

[0145] Furthermore, through the aforementioned automation and digitalization solutions, the system helps enhance condition monitoring and, when combined with appropriate data analytics, facilitates cost-effective preventative maintenance, thereby further ensuring machine uptime (reliability).

Claims

1. A system comprising a plurality of movable closed-loop transport units and a main transport unit, wherein the movable closed-loop transport units are adapted to provide one or more packaging material components to the main transport unit and / or perform packaging process operations on a given package in assembly present at the main transport unit, wherein the movable closed-loop transport units are three-dimensionally movable relative to the main transport unit. in, The control system is capable of controlling the three-dimensional movement of the movable closed-loop transport unit to simultaneously provide one or more packaging material components to the given package being assembled and / or simultaneously provide packaging process operations to the given package being assembled.

2. The system of claim 1, wherein each of the movable closed-loop transport units includes a plurality of tools mounted on individually motion-controlled thrusters, the plurality of tools providing the one or more packaging material components to the given package being assembled and / or providing the packaging process operation to the given package being assembled.

3. The system of claim 2, wherein the plurality of tools are wirelessly controllable and / or wirelessly powered.

4. The system of claim 2, wherein the control system is configured to synchronize the pace and spacing of the plurality of tools with the transport of the given package being assembled on the main transport unit.

5. The system according to any one of claims 1 to 4, wherein the control system is configured to control the three-dimensional movement of the movable closed-loop transport unit relative to the given package being assembled.

6. The system according to any one of claims 2 to 4, wherein the main transport unit includes the plurality of tools on individually motion-controlled thrusters for providing packaging process operations to the given package being assembled, and wherein the control system is capable of controlling the three-dimensional movement of one or more of the movable closed-loop transport units, the main transport unit and a corresponding number of tools on the individually motion-controlled thrusters, to simultaneously provide one or more packaging material components to the given package being assembled and / or simultaneously provide packaging process operations to the given package being assembled.

7. A packaging machine for assembling packaging, comprising the system according to any one of claims 1 to 6.

8. A method for assembling packaging, comprising the following steps: The process involves providing one or more packaging material components to at least one of a plurality of three-dimensional movable closed-loop transport units; transporting the components to a main transport unit via the at least one of the movable closed-loop transport units; and moving the movable closed-loop transport units in a three-dimensional manner relative to the main transport unit. The control system is capable of controlling the three-dimensional movement of the movable closed-loop transport unit to simultaneously provide one or more packaging material components to a given package being assembled and / or simultaneously provide packaging process operations to the given package being assembled.

9. A method for assembling packaging, comprising the following steps: The process involves providing a given package under assembly to a main transport unit; performing packaging operations on the given package under assembly via at least one of a plurality of movable closed-loop transport units; and moving the movable closed-loop transport unit in three dimensions relative to the main transport unit. The control system is capable of controlling the three-dimensional movement of the movable closed-loop transport unit to simultaneously provide one or more packaging material components to the given package being assembled and / or simultaneously provide packaging process operations to the given package being assembled.

10. The method for assembling packaging according to claim 9, wherein the step of providing one or more packaging material components or the step of performing the packaging process operation comprises: (i) Supplying and / or assembling packaging material components; (ii) Supplying and / or loading one or more primary articles into secondary packaging, or supplying and / or loading one or more secondary packages into tertiary packaging; (iii) Moving one or more packaging components or a portion thereof in a given orientation; (iv) Securing one or more packaging components to the given package being assembled; (v) Rotating the given package during assembly or the final assembled package; (vi) Inspecting the package and / or coding the package; (vii) Package components and all combinations thereof in the process of accelerating, decelerating, cutting, stretching, compressing, flattening, folding, erecting, gluing, decorating, assembling.

11. A system comprising a plurality of movable closed-loop transport units and a main transport unit, wherein the movable closed-loop transport units are adapted to provide one or more article components to the main transport unit and / or perform process operations on a given article in assembly present on the main transport unit, wherein the movable closed-loop transport units are three-dimensionally movable relative to the main transport unit. in, The control system is capable of controlling the three-dimensional movement of the movable closed-loop transport unit to simultaneously provide one or more packaging material components to a given package being assembled and / or simultaneously provide packaging process operations to the given package being assembled.

12. A machine for assembling articles, comprising at least the system according to claim 11.

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