Blank joining module with improved ergonomics

Abstract

The present invention relates to a feeder module for a blank joining module, the feeder module comprising an upper feeder device and a lower feeder device, each feeder device comprising a loading surface configured to receive a stack of blanks, and each feeder device being configured to sequentially discharge blanks in a transport direction, and wherein the upper feeder device is displaceable in the transport direction such that the upper loading surface is horizontally offset relative to the lower loading surface.

Description

Technical Field

[0001] The present invention relates to a converting machine for producing folding boxes and similar packaging containers. In particular, the present invention relates to a blank joining module configured to join two blanks before folding the blanks together. Background Art

[0002] Converting machines such as folder-gluers are used in the production of packaging items such as paperboard and cartons. These machines consist of multiple stations that fold and glue blanks to form boxes, then count, stack and collate the boxes into batches.

[0003] Folder-gluers can be configured to produce many different types of folding boxes and packaging containers. One type of box consisting of two blanks joined together is often referred to as a "shelf-ready" box. A shelf-ready box consists of an outer blank and an inner blank that are folded and glued together. The inner blank can serve as an inner container for the items to be stored, while the outer blank can serve as protection during transport. This type of box is often used in supermarkets and shops, where the inner container is placed on the shelf and the items are placed inside.

[0004] When a packaging container is produced with a plurality of blanks connected together, a blank joining module with a double feeder is required. Specifically, a dedicated feeder is required for each of the first and second blanks. An example of a blank joining module comprising an upper feeder and a lower feeder is described in document EP2072241.

[0005] For large work batches, the machine operator needs to continuously load new blanks in the form of stacks into the upper feeder and the lower feeder. When the blanks in the lower feeder have a considerable horizontal length in the blank transport direction, it is particularly difficult for the machine operator to approach the upper feeder. Summary of the invention

[0006] In view of the prior art, an object of the present invention is to provide a blank joining module which is convenient for approaching a feeder.

[0007] According to a first aspect of the present invention, a blank joining module for a conversion machine is provided, the blank joining module comprising a chassis, an upper feeder device having an upper loading surface, and a lower feeder device having a lower loading surface, each feeder device being configured to receive a stack of blanks and discharge the blanks one by one in a transport direction, and wherein the upper loading surface of the upper feeder device can be shifted in the transport direction so that the upper loading surface is horizontally offset relative to the lower loading surface.

[0008] The invention is based on the recognition that an upper feeder arrangement with a displaceable loading surface provides improved lateral access to the upper feeder and that this access can be optimized for upper and lower blanks of different formats.

[0009] The transport direction is horizontal. The transport direction extends between the inlet and the outlet of the conversion machine. The upper blank has an inclined transport direction and the lower blank has a horizontal transport direction.

[0010] The horizontal transport direction of the lower blank may include a deviation of 0-15 degrees from the horizontal plane. The transport direction of the upper feeder device includes a vertical component and a horizontal component. When the upper loading surface is displaced, a horizontal displacement component in the transport direction is manifested. However, due to the inclined transport path, the upper feeder device is also displaced vertically. Therefore, the horizontal displacement component of the upper loading surface enables the upper loading surface to be displaced upstream and downstream in the transport direction.

[0011] The horizontal offset means that the upper loading surface of the upper feeder device can be positioned further upstream in the transport direction than the loading surface of the lower feeder device. This means that the rear edge of the upper loading surface can be positioned horizontally offset from the rear edge of the lower loading surface. However, if the upper and lower blanks have different lengths in the transport direction, this allows to align the rear edge of the stack in the upper feeder device vertically with the rear edge of the stack in the lower feeder device. The upper loading surface can be moved upstream and downstream in the transport direction. The upper loading surface can thus be moved closer to the machine operator when the machine operator loads the upper and lower loading surfaces from an upstream position.

[0012] In one embodiment, the blank engagement module further comprises an upper alignment device connected to the upper feeder device, wherein the upper alignment device is provided with a variable length, and wherein the upper feeder device is connected to the upper alignment device. Preferably, there is a fixed connection between the upper feeder device and the upper alignment device.

[0013] In one embodiment, the upper alignment device includes an upper pressing member and an upper conveyor belt configured to receive the blank therebetween, the upper pressing member and the upper conveyor belt being supported by a common support structure, wherein the support structure includes an extendable and retractable connection mechanism configured to allow the longitudinal length of the upper pressing member and the longitudinal length of the upper conveyor belt to be uniformly modified and modified to the same distance.

[0014] In one embodiment, the longitudinal length of the upper pressing member and the upper conveyor belt varies with the longitudinal displacement of the upper feeder device.

[0015] In one embodiment, the connection structure comprises a plurality of frame members interconnected by pivot links, and wherein the pivot links are configured to distribute the displacement of the upper feeder device into equidistant displacements between the frame members.

[0016] In one embodiment, the frame member includes a first cantilever extension and a second cantilever extension, and wherein the first cantilever extension is connected to a pressing roller of the upper pressing member and the second cantilever extension is connected to a guide roller configured to maintain a shape of the upper conveyor belt.

[0017] In one embodiment, the feeder module comprises a slide rail connection between the upper feeder assembly and the chassis.

[0018] In one embodiment, the blank engaging module further comprises a control circuit and a shift motor, wherein the control circuit is configured to determine a desired longitudinal position of the upper feeder device based on a longitudinal length of the lower blank in the lower feeder device, and wherein the shift motor is configured to automatically shift the upper feeder device to a horizontally offset position relative to the lower feeder device.

[0019] In one embodiment, the blank engagement module further comprises an adjustable base attached to the chassis and movable in the transport direction, and wherein the base comprises at least one first stepping surface movable between an extended position located in front of the feeder device and a retracted position in which at least one stepping surface is located below the feeder device.

[0020] In one embodiment, the base further comprises a second stepping surface, and wherein the second stepping surface is connected to the first stepping surface in a slide rail connection, and wherein the second stepping surface is movable in a vertical direction relative to the transport direction.

[0021] In one embodiment, when the locking mechanism is activated, the base is locked in the extended configuration.

[0022] In one embodiment, the locking mechanism is manually activated by a button, and wherein when the button is released, the locking mechanism is automatically activated.

[0023] In one embodiment, the base is connected to a drive motor, allowing an operator to extend and retract the base by automatic displacement of the drive motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present invention will now be described with reference to the accompanying drawings, in which like features are indicated by like reference numerals, and in which:

[0025] - Figure 1 is a schematic diagram of a converting machine configured as a folder-gluer;

[0026] - Figure 2a is a schematic perspective view of a folding box in a shelf-easy box configuration;

[0027] - Figure 2b It is used for production Figure 2a A plan view of a blank composed of a folding box;

[0028] - Figure 3a is a schematic perspective view of a blank joining module according to an embodiment of the present invention;

[0029] - Figure 3b and Figure 3c yes Figure 3a A schematic cross-sectional detail of a base of a blank engagement module;

[0030] - Figure 4 yes Figure 3a A cross-sectional view of a blank joining module;

[0031] - Figure 5 is a schematic cross-sectional view of a feeder unit according to an embodiment of the present invention;

[0032] - Figure 6 is a schematic cross-sectional view of a lower alignment device of a blank engagement module;

[0033] - Figure 7a and Figure 7b a schematic cross-sectional view of an upper alignment device of a blank engagement module, viewed from a first side and a second side, respectively; and

[0034] - Figure 7c yes Figure 7a and Figure 7b Schematic perspective view of the upper alignment device. DETAILED DESCRIPTION

[0035] With reference to the accompanying drawings, in particular with reference to Figure 1 , which shows a converting machine 1 in the form of a folder-gluer 1. The folder-gluer 1 is configured to receive an upper stack S2 and a lower stack S1 of blanks 2, join the blanks 2, and then fold and glue them together to form a folding box 2" or other composed packaging container.

[0036] The folder-gluer 1 can produce several types of folding boxes 2' and packaging containers. Figure 2a One type of box 2' is shown, which may also be referred to as a "shelf-friendly" box 2'. Figure 2b As shown, this type of box 2 'is composed of two blanks 2b, 2a joined together. One blank 2a can form an inner container, and the other blank 2b can form an outer container. In use, the outer container can be removed manually, while the inner container still holds the items to be stored.

[0037] To produce this type of composed folding box 2 ″, a composed blank 2 ′ is first formed from a first blank 2 a and a second blank 2 b in a folder-gluer 1 . Subsequently, the composed blank 2 ′ is subjected to folding and gluing operations.

[0038] like Figure 1 As shown, the folding and gluing machine 1 includes a series of workstations in the form of different modules. In the transport direction T extending from the entrance A to the exit B, these modules may include: a blank joining module 10, a folding pre-breaking module 12, a bonding module 15 and a folding module 16. The folding and gluing machine 1 may also include a main user interface 11 and a quality control system 18. After the bonding and folding modules, a conveying module and an adjustment section 20 may be provided to count the folding boxes 2' of the shingled flow and divide them into separate batches. The conversion machine 1 also includes a conveying system 19, which includes a conveyor such as an endless belt and a roller, and the conveying system is configured to transport the first blank 2a and the second blank 2b in the transport direction T. The conversion machine 1 also includes a control circuit 80, which is configured to control the operation of the blank joining module 10.

[0039] The blank joining module 10 enables the folder-gluer 1 to produce composed blanks 2'. Figure 3a and Figure 4 As shown, the blank bonding module 10 includes a feeder unit 32 , an alignment unit 34 , a bonding device 100 , a registration control device 36 , and a bonding conveyor device 38 .

[0040] The feeder unit 32 comprises a lower feeder device 32a and an upper feeder device 32b. The upper feeder device 32b and the lower feeder device 32a are configured to feed the blanks 2a, 2b one by one along the transport direction T, respectively.

[0041] The upper feeder device 32b is configured to supply a first blank 2b, also referred to as an "upper blank" 2b, from a stack S2 located on an upper loading surface 33b. The lower feeder device 32a is configured to supply a second blank 2a, also referred to as a "lower blank" 2a, from a stack S1 located on a lower loading surface 33a in the lower feeder device 32a.

[0042] The upper loading surface 33b is located directly above the lower loading surface 33a. In order to facilitate access to the upper loading surface 33b, the loading surface 33b of the upper feeder device 32b can be displaced in the longitudinal direction L and thus in the transport direction T of the upper blank 2b. The longitudinal direction L is defined by the longitudinal extension of the upper loading surface 33b. Therefore, the longitudinal direction L is inclined downward in the transport direction T.

[0043] The upper loading surface 33b can be displaced to a horizontally offset position relative to the lower loading surface 33a. This can allow the trailing edge of the blank 2b on the upper loading surface 33b to be vertically aligned with the trailing edge of the blank 2a on the lower loading surface 33a. Alternatively, the trailing edge of the upper blank 2b can be moved further upstream in the transport direction T, thereby reducing the horizontal distance between the trailing edge of the upper blank 2b and the trailing edge of the lower blank 2a. In this way, the upper loading surface 33b can be positioned closer to the machine operator.

[0044] like Figure 3a , Figure 4 and Figure 5 As best shown, the upper feeder device 32b is slidably mounted on a chassis (i.e., structural frame) 40 of the blank engagement module 10. The connection between the upper feeder device 32b and the chassis 40 can be achieved by a sliding connection. The sliding connection can include a slide rail 42 and a slider 41. The upper feeder device 32b can be moved along the slide rail 42 by a motor 44.

[0045] The motor 44 can perform the automatic shifting of the upper feeder device 32b. The control circuit 80 of the blank engagement module 10 can automatically operate the motor 44 to move the upper feeder device 32b to a predetermined operating position calculated according to the longitudinal length La of the lower blank 2a in the lower feeder device 32a. The longitudinal length La is the length of the lower blank 2a in the transport direction T. Preferably, the upper feeder device 32b is shifted so that the upper stack and the lower stack (in the transport direction T) of the blank 2 in the corresponding feeder devices 32a, 32b are vertically aligned. Alternatively, the upper feeder device 32b can be shifted based on the manual input to the main user interface 11. In this way, the operator can decide the position of the upper feeder device 32b.

[0046] like Figure 4 As shown, an alignment unit 34 is arranged downstream of the feeder unit 32 in the transport direction T. The alignment unit 34 is configured to align the upper blank 2b and the lower blank 2a laterally to their respective predetermined lateral positions. The predetermined lateral positions are defined by the positions of the longitudinal crease lines 4 and the positions of the folding tools in the conversion machine 1. Thus, the predetermined lateral positions enable the composed blank 2' to be positioned according to the assembly instructions and the conversion machine 1 to fold the composed blank 2' according to the crease lines 4.

[0047] Therefore, the alignment unit 34 is configured to align the upper blank 2b and the lower blank 2a in a direction perpendicular to the transport direction T. In this way, when the blanks 2a, 2b contact each other at the joining point J, the upper blank 2b is in the correct lateral position with the lower blank 2a.

[0048] The gluing device 100 is located upstream of the joining point J. The gluing device 100 is arranged to distribute glue on the top side of the lower blank 2a so that the glue is located between the upper blank 2b and the lower blank 2a when they are in contact with each other.

[0049] The alignment unit 34 comprises an upper alignment device 34b configured to align the upper blank 2b and a lower alignment device 34a configured to align the lower blank 2a. The upper alignment device 34b and the lower alignment device 34a are provided with respective distal upstream connection ends 35b, 35a, which are preferably fixedly connected to the upper feeder device 32b and the lower feeder device 32a.

[0050] The lower alignment device 34a is configured to transport the lower blank 2a along a substantially horizontal transport path Pa. Thus, the horizontal transport path may deviate by 0-15 degrees relative to the horizontal plane. Figure 6 As best shown, the lower alignment device 34a includes an upper pressing member 60a, a lower conveyor 61a and a guide (not shown). The lower conveyor 61a includes an endless conveyor belt 62a having a contact length Lca, which is configured to contact and drive the lower blank 2a forward along the transport direction T.

[0051] like Figure 7a-7c As best shown, the upper alignment device 34b comprises an upper pressing member 60b and an upper conveying device 61b. The upper conveying device 61b comprises an endless upper conveyor belt 62b having a contact length Lcb, which is configured to contact the upper blank 2b and drive the upper blank 2b forward along the transport direction T. The guide 63 is arranged such that its longitudinal extension coincides with the transport direction T. The upper pressing member 60b and the upper conveying device 61b are arranged at an angle relative to the transport direction T so that the lateral edge of the lower blank 2a abuts against the guide 63.

[0052] Thus, the upper alignment device 34b is configured similarly to the lower alignment device 34a. However, the upper alignment device 34b is provided with a variable contact length Lcb in the transport direction T. The upper alignment device 34b further includes a compensation mechanism 39 that may be in the return path Pr of the upper conveyor belt 62b. The compensation mechanism 39 is configured to change the length of the upper endless conveyor belt 62b in the return path to accommodate changes in the contact length Lcb.

[0053] The upper alignment device 34b comprises a movable distal end 35b connected to the upper feeder device 32b and a fixed distal end 37b connected to the chassis 43 of the alignment device 34b. Thus, the movable distal end 35b is movable in the transport direction of the upper blank 2b. The chassis 43 of the upper alignment device is connected to the chassis of the blank joining module 10. This allows displacement of the upper feeder device 32b in the longitudinal direction L while maintaining a fixed connection with the upper alignment device 34b.

[0054] like Figure 7b and Figure 7c As shown, the upper conveying device 61b of the upper alignment device 34b also includes a support structure 69, which is configured to support the upper conveyor belt 62b. The support structure 69 includes a plurality of guide rollers 67 (see Figure 7a), the upper conveyor belt 62b is mounted on guide rollers 67. The guide rollers 67 are attached to the frame members 70. The connecting mechanism 68 connects adjacent frame members 70 to each other. The connecting mechanism 68 is extendable so that the distance between the frame members 70 can be modified. The frame members 70 can be displaced in the transport direction T. Each guide roller 67 is attached to the frame member 70 and arranged in a straight line. The connecting mechanism 68 allows the contact length Lcb to be changed while all guide rollers 67 remain in contact with the upper blank 2b. The contact length Lcb can be changed between a retracted position Lcb_min and an extended position, in which the connecting mechanism 68 has its shortest length and in which the connecting mechanism 68 has its longest length Lcb_max.

[0055] Preferably, the connecting mechanism 68 includes a plurality of pivotable links 74a, 74b that allow equidistant displacement of the frame member 70. The pivotable connecting links 74a, 74b can be provided by two linear elements. The pivotable connecting links 74a, 74b are connected to each frame member 70 in a central pivot 75. The pivotable connecting links 74a, 74b are also connected to each other in an upper pivot 76 and a lower pivot 77. The upper pivot 76 and the lower pivot 77 are movable in the longitudinal direction L.

[0056] By connecting the frame member 70 to the central pivot 75, the horizontal position of the central pivot 75 is maintained constant.

[0057] The support structure has a first distal end 35 b connected to the upper feeder device 32 b and a second distal end 37 b connected to the base plate 40 of the blank engagement module 10 .

[0058] like Figure 7c As best shown, each frame member 70 includes a first cantilever extension 70a, a second cantilever extension 70b, and a frame member bracket 70c to which the first and second cantilever extensions are connected.

[0059] The guide roller 67 of the upper conveyor belt 62b is attached to the first cantilever extension 70a, and the pressure roller 66 is attached to the second cantilever extension 70b. The upper blank 2b is received between the pressure roller 66 and the upper conveyor belt 62b. The first cantilever extension 70a and the second cantilever extension 70b extend horizontally and parallel to each other. The second cantilever extension 70b is arranged directly above the first cantilever extension 70a.

[0060] The second cantilever extension 70b may be supported by an upper rail 71b and the second cantilever extension 70b may be supported by a lower rail 71a. The rails 71a, 71b may be in the form of longitudinal bars disposed below the first and second cantilever extensions 70a, 70b, respectively.

[0061] The distal entrance end 35b of the upper alignment device 34b may include an attachment bracket 79 configured to be attached to the upper feeder device 32b. The attachment bracket 79 may also provide a fixed structure to form an entrance portion I for the upper press roller 66 and the guide roller 67 of the conveyor belt 62b. The attachment bracket 79 provides a fixed connection with the cantilever extensions 70b, 70c so that the entrance portion I has a constant length regardless of whether the connection mechanism 68 is extended or retracted. This ensures that there is a sufficiently long entrance portion I into the upper alignment device 34b so that the upper blank 2b has completely left the upper feeder device 32b before the upper blank 2b is tilted and aligned to the guide member 63. The distal center pivot 79a is attached to the attachment bracket 79. The second distal center pivot 79b is attached to the frame member 77 of the upper alignment module 34b.

[0062] To further facilitate access to the upper feeder device 32b, the blank engagement module 10 may include a modular base 50. Figure 3a-3c As best shown, the base 50 includes at least a first stepping surface 52a. Preferably, the base 50 also includes a second stepping surface 52b located on top of the first stepping surface 52a.

[0063] The second step surface 52b may be preferably smaller than the first step surface 52a. The second step surface 52b may be connected to the first step surface 52a via a slide rail connection 56. The first step surface 52a may be movable in the transport direction T, and the second step surface 52b may be movable in a direction perpendicular to the transport direction T.

[0064] The first step surface 52a is provided with a displacement device 53 so that it can be moved in a retracted position RP (see Figure 3a ) and an extended position EP located in front of the conversion machine 1. The shifting device 53 may be in the form of rollers or slide rails. In the extended position EP, the first stepping surface 52a and the second stepping surface 52b are positioned so that an operator can stand on the first and second stepping surfaces 52a, 52b and more easily approach the loading surface 33b of the upper feeder device 32b. Preferably, the first stepping surface 52a and the second stepping surface include a locking mechanism 57. This allows the first and second stepping surfaces 52a, 52b to be locked in the extended position EP and reduces the risk of unintentional movement.

[0065] The first stepping surface 52a may be connected to a drive mechanism comprising a shifting motor 54. The shifting device 53 and the drive mechanism are attached to the structural frame 40 of the blank joining module 10.

[0066] Manual displacement of the first stepping surface 52a may be initiated by activating a button 55 located on the handle of the modular base 50. Alternatively, the first and second stepping surfaces 52a, 52b may be automatically displaced between the retracted position and the extended position based on information from the control circuit 80.

[0067] The modular base 50 can cooperate with the upper extendable upper feeder device 32b. The upper feeder device 32b provides improved horizontal access to the upper feeder device, while the base provides improved vertical access to the upper feeder device 32b.

Claims

1. A blank joining module for a conversion machine, the blank joining module comprising a chassis (40), an upper feeder device (32b) having an upper loading surface (33b) and a lower feeder device (32a) having a lower loading surface (33a), the upper feeder device being configured to receive a stack (S2) of upper blanks (2b), the lower feeder device being configured to receive a stack (S1) of lower blanks (2a), the feeder devices (32a, 32b) being configured to discharge corresponding upper and lower blanks (2a, 2b) in sequence along a transport direction (T), and wherein the upper loading surface of the upper feeder device is displaceable in the transport direction so that the upper loading surface is horizontally offset relative to the lower loading surface.

2. The blank joining module according to claim 1 further comprises an upper alignment device (34b) connected to the upper feeder device, wherein the upper alignment device is provided with a variable length, and wherein the upper feeder device is connected to the upper alignment device.

3. A blank joining module according to the preceding claim, wherein the upper alignment device includes an upper pressing member (60a) and an upper conveyor belt (62b), which are configured to receive the blank between them, and the upper pressing member and the upper conveyor belt are supported by a common support structure (69), wherein the support structure includes an extendable and retractable connecting mechanism (68), which is configured to allow the longitudinal lengths of the upper pressing member and the upper conveyor belt to be uniformly modified and modified to the same distance.

4. The blank engaging module according to the preceding claim, wherein the longitudinal length of the upper pressing member and of the upper conveyor belt is modified upon longitudinal displacement of the upper feeder device.

5. A blank joining module according to the preceding claim, wherein the connecting structure comprises a plurality of frame members (70) interconnected by pivot links (74a, 74b), and wherein the pivot links are configured to distribute the displacement of the upper feeder device as equidistant displacements between the frame members.

6. A blank joining module according to the preceding claim, wherein the frame member comprises a first cantilever extension (70a) and a second cantilever extension (70b), and wherein the first cantilever extension is connected to a pressure roller (66) of the upper pressing member, and the second cantilever extension is connected to a guide roller (67) configured to maintain the shape of the upper conveyor belt (62b).

7. A blank engagement module according to any one of the preceding claims, wherein the feeder module comprises a slide rail connection between the upper feeder device and the chassis.

8. The blank joining module according to any one of the preceding claims further includes a control circuit (80) and a shift motor (44), wherein the control circuit is configured to determine the desired longitudinal position of the upper feeder device based on the longitudinal length (La) of the lower blank in the lower feeder device, and wherein the shift motor is configured to automatically shift the upper feeder device to a horizontally offset position relative to the lower feeder device.

9. A blank joining module according to any one of the preceding claims, wherein the blank joining module also includes an adjustable base (50), which is attached to the chassis and can be moved in the transport direction, and wherein the base includes at least one first stepping surface (52a), which can be moved between an extended position (EP) located in front of the feeder device (32a, 32b) and a retracted position (RP) in which the at least one stepping surface is located below the feeder device (32a, 32b).

10. A blank joining module according to any one of the preceding claims, wherein the base further comprises a second stepping surface (52b), and wherein the second stepping surface is connected to the first stepping surface via a slide rail connection (56), and wherein the second stepping surface is movable in a vertical direction relative to the transport direction.

11. A blank engagement module according to claim 9 or 10, wherein upon activation of a locking mechanism (57) the base is locked in the extended configuration.

12. The blank engagement module according to the preceding claim, wherein the locking mechanism is manually activated by a button (55), and wherein the locking mechanism is automatically activated when the button is released.

13. The blank joining module according to the preceding claim, wherein the base is connected to a drive motor (54) allowing an operator to extend and retract the base by automatic displacement of the drive motor.

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