A fully automatic cartoning machine

Abstract

This utility model discloses a fully automatic cartoning machine, including a machine base, a conveying mechanism, a stacking platform, and a control frame supported by support columns above the machine base. The control frame is equipped with a horizontal moving mechanism driven by a first motor, and a lifting mechanism is mounted on the moving seat above it. The output end of the lifting mechanism is connected to a gripping mechanism driven by a bidirectional lead screw and forcibly guided by parallel linear guides. A machine vision system synchronously identifies the coordinates of the products on the stacking platform and the boxes on the conveyor belt using an industrial camera. This utility model provides a high-rigidity motion reference through a unique "gantry" frame structure. Utilizing visual positioning and closed-loop control of three-axis motion, it achieves precise and stable gripping and adaptive placement of products. The overall structure is compact, well-coordinated, and highly adaptable, effectively solving the problems of low precision, poor flexibility, and loose layout in traditional cartoning machines.

Description

Technical Field

[0001] This utility model relates to the field of packaging machinery technology, specifically a fully automatic cartoning machine. Background Technology

[0002] A cartoning machine is an automated device that automatically fills products into pre-made packaging boxes. It is widely used in pharmaceuticals, medical devices, food, cosmetics, and electronics. In practical applications, those skilled in the art have found that existing cartoning machines generally suffer from the following technical problems that urgently need improvement:

[0003] Firstly, regarding the overall structural layout and rigidity, many existing devices adopt a modular approach, simply assembling the drive mechanism, gripping mechanism, and conveying mechanism. This results in a loose overall layout and a large footprint. This layout not only leads to poor power transmission and motion coordination between modules, affecting cycle time and operating efficiency, but also, due to the lack of a high-rigidity, unified reference frame, the equipment is prone to deformation or vibration during long-term operation, causing a decrease in motion accuracy. Furthermore, it significantly complicates installation, commissioning, and daily maintenance.

[0004] Secondly, in terms of positioning and gripping accuracy, mainstream cartoning machines typically rely on preset mechanical limits, fixed-track cam mechanisms, or simple Cartesian coordinate systems for operation. This approach has significant drawbacks: on the one hand, it has extremely low tolerance for errors in the initial placement of products and empty boxes, requiring extremely high consistency in feeding. Any slight deviation can lead to gripping failure, collisions, or inaccurate placement, causing downtime and waste. On the other hand, mechanical parts inevitably wear down after prolonged high-frequency operation, causing a gradual loss of the original positioning accuracy, resulting in problems such as unstable gripping and placement drift, seriously affecting the long-term stability of packaging quality.

[0005] Furthermore, in terms of equipment adaptability and flexibility, the aforementioned solutions relying on fixed mechanical structures exhibit serious shortcomings when faced with changes in product specifications or box shapes. Operators typically need to spend a significant amount of time replacing mechanical parts, adjusting stroke limits, and performing tedious calibration work, resulting in long downtime for equipment changeovers and making it difficult to adapt to the demands of modern flexible production involving small batches and diverse product types. Although high-precision solutions using multi-degree-of-freedom industrial robots exist on the market, capable of adapting to different tasks through offline programming, their core components are expensive, their system structures are complex, and maintenance is difficult.

[0006] Therefore, developing a fully automatic cartoning machine with a compact structure, high rigidity, precise and stable positioning, good production adaptability, and controllable cost has become an urgent problem to be solved in this field. Utility Model Content

[0007] To solve the above-mentioned technical problems, this utility model provides a fully automatic cartoning machine.

[0008] This application provides the following technical solution:

[0009] A fully automatic cartoning machine includes a machine base, a stacking platform disposed at one end of the machine base, a conveying mechanism disposed at the other end of the machine base, and a control frame fixed above the machine base by multiple support columns.

[0010] A horizontal moving mechanism, mounted on the control frame, is used to provide drive in the X-axis direction;

[0011] A lifting mechanism is mounted on the horizontal moving mechanism to provide drive in the Z-axis direction;

[0012] A gripping mechanism is provided at the output end of the lifting mechanism to provide drive in the Y-axis direction and perform product gripping and release.

[0013] And a machine vision positioning system, including an industrial camera fixed on a control frame and a controller electrically connected to each part;

[0014] The field of view of the industrial camera covers the stacking platform and the box placement area;

[0015] The controller is configured to control the horizontal moving mechanism, lifting mechanism and gripping mechanism to complete automatic pick-and-place operations based on the product and box coordinates identified by the industrial camera.

[0016] Preferably, a mounting plate is fixed to one side wall of the control frame, a first motor is fixed on the mounting plate, and a rectangular through slot is provided on the top wall of the control frame.

[0017] Preferably, the horizontal moving mechanism includes: a one-way lead screw driven by the first motor; at least one guide rod arranged parallel to the one-way lead screw; and a moving seat that is screwed to the one-way lead screw via a lead screw nut and slidably engaged with the guide rod via a linear bearing.

[0018] Preferably, the lifting mechanism is an electric push rod, the cylinder of which is fixed on the movable seat and passes through the rectangular through slot; the piston rod extends vertically downward and the clamping mechanism is fixed at its bottom end.

[0019] Preferably, the clamping mechanism includes: a clamping seat fixed to the output end of the lifting mechanism; a bidirectional lead screw driven by a second motor and having oppositely oriented threads at both ends, the bidirectional lead screw being supported on the clamping seat by bearings; two parallel linear guide rails fixed to the clamping seat and distributed on both sides of the bidirectional lead screw; two moving blocks respectively screwed onto the threads at both ends of the bidirectional lead screw; four sliders slidingly engaged with the linear guide rails and symmetrically distributed on the two linear guide rails; and each moving block being fixedly connected to two corresponding sliders on the left and right sides; and two clamping plates, each clamping plate being fixed to the bottom of one of the moving blocks by a connecting bracket.

[0020] Preferably, the clamping surface of the clamping plate is covered with a flexible pad.

[0021] Preferably, the conveying mechanism includes a conveyor platform, and a belt conveyor is installed in the platform body of the conveyor platform.

[0022] Preferably, the industrial camera is equipped with a ring LED light source, and the controller is a PLC or an industrial embedded computer, and can be further electrically connected to the conveying mechanism.

[0023] Compared with the prior art, the beneficial effects of this utility model are:

[0024] 1. Achieved fully automated high-precision boxing based on visual feedback: Through the closed-loop cooperation of the three-axis motion system integrated on the "gantry" frame and machine vision, the entire process from identification, grasping, handling to placement is automated and intelligent, with high positioning accuracy, which greatly improves production efficiency and boxing consistency.

[0025] 2. High structural rigidity and stable, precise operation: The unique "gantry" frame and top-integrated horizontal moving mechanism design provide a solid foundation for the equipment's movement. The gripping mechanism adopts a rigid guiding scheme of "bidirectional lead screw + double-sided parallel linear guide rails," eliminating swaying and deflection during the gripping process and ensuring the accuracy and reliability of grasping and releasing.

[0026] 3. Compact Layout and Excellent Coordination: The horizontal moving mechanism is built into the control frame beam, the lifting mechanism directly connects to the work area through the top slot, and the clamping mechanism performs suspended operations. This three-dimensional spatial layout makes the equipment structure very compact, the movement path optimized, interference-free, and highly efficient. All modules are built on a unified rigid frame, forming a highly coordinated and coherent automated work unit, which is easy to integrate into the production line and convenient to maintain.

[0027] 4. Excellent production adaptability: Through the programmable vision system and servo drive system, it can be quickly adjusted to adapt to different specifications of products and boxes, reducing changeover time and costs, and meeting the needs of flexible production. Attached Figure Description

[0028] Figure 1 This is a first-view structural diagram of a fully automatic cartoning machine according to the present invention;

[0029] Figure 2 This is a second-view structural diagram of a fully automatic cartoning machine according to the present invention;

[0030] Figure 3 This is a third-view structural diagram of a fully automatic cartoning machine according to the present invention;

[0031] Figure 4 This utility model Figure 3 A magnified structural diagram of point A in the middle.

[0032] In the diagram: 1. Machine base; 2. Conveyor table; 3. Belt conveyor; 4. Box body; 5. Stacking table; 6. Support column; 7. Control frame; 8. Rectangular through slot; 9. Mounting plate; 10. First motor; 11. One-way lead screw; 12. Moving seat; 13. Electric push rod; 14. Guide rod; 15. Clamping seat; 16. Second motor; 17. Two-way lead screw; 18. Linear guide rail; 19. Moving block; 20. Slider; 21. Connecting frame; 22. Clamping plate. Detailed Implementation

[0033] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0034] Please see Figures 1 to 4 This utility model provides a technical solution: a fully automatic cartoning machine, including a base 1, which forms the basic support platform for the entire equipment. A stacking platform 5 is fixed at the left end of the base 1 for neatly stacking products to be cartoned. A conveying mechanism is provided at the right end of the base 1, which includes a conveyor table 2 and a belt conveyor 3 integrated into the table body for conveying empty boxes 4 and transporting filled boxes 4 out.

[0035] Frame Structure: Above the machine base 1, a rectangular control frame 7 is supported by four vertically fixed support columns 6. These support columns 6, together with the control frame 7 and the machine base 1, form a robust "gantry" or "bridge" frame structure. This structure supports the main moving parts above, leaving ample operating space below, allowing the stacking platform 5 and conveying mechanism to be arranged on the machine base 1 without interference. Not only is the overall structure compact, saving floor space, but more importantly, the "gantry" frame possesses extremely high overall rigidity and stability.

[0036] Horizontal Movement Mechanism (X-axis): A horizontal movement mechanism is installed within the top crossbeam of the control frame 7. Specifically, a one-way lead screw 11 is horizontally mounted within the inner cavity of the control frame 7 via a bearing seat, and a guide rod 14 parallel to it is fixed within the control frame 7. The rear end of a movable seat 12 is screwed to the one-way lead screw 11 via a ball screw nut, and the front end is slidably mounted on the guide rod 14 via a linear bearing. A mounting plate 9 is welded to the right side wall of the control frame 7, and a first motor 10 (preferably a servo motor) is fixed thereon, driving the one-way lead screw 11 to rotate via a coupling. Thus, the entire horizontal movement mechanism is integrated within the top crossbeam of the "gantry" frame, providing a closed and protected structure and smooth operation.

[0037] Lifting Mechanism (Z-axis) and Channel Design: An electric push rod 13 is fixedly mounted on the top of the movable seat 12. A rectangular through slot 8 is formed on the top wall of the control frame 7 corresponding to the movement trajectory of the electric push rod 13. This through slot design allows the piston rod of the electric push rod 13 and its lower load to smoothly pass through the top wall of the control frame 7 under the drive of the movable seat 12 and directly enter the working area below. This design avoids setting up a complex suspension structure on the outside of the control frame 7, making the transmission chain of Z-axis movement the shortest, the rigidity the best, and effectively reducing swaying and cumulative errors.

[0038] Clamping Mechanism (Y-axis Clamping): The piston rod end of the electric push rod 13 is connected to the clamping seat 15. The core of the clamping mechanism lies in its high-precision, non-deflection clamping action. Inside the cavity of the clamping seat 15, a bidirectional lead screw 17 is supported by bearings and driven by a second motor 16 (preferably a servo motor) fixed to the rear side wall of the clamping seat 15. Crucially, two high-precision linear guides 18 are fixed in parallel on both sides of the bidirectional lead screw 17. Two moving blocks 19 respectively engage with two sections of threads with opposite directions of rotation on the bidirectional lead screw 17. The left and right sides of each moving block 19 are fixed to the corresponding sliders 20, thereby rigidly connecting the moving blocks 19 and the sliders 20 of the linear guides 18 into one unit. This design ensures that when the moving blocks 19 move towards or away from each other under the drive of the bidirectional lead screw 17, they are completely guided by the linear guides 18, eliminating rotation or lateral sway that may be caused by lead screw backlash or uneven force. Each movable block 19 has a clamping plate 22 mounted on its bottom via an L-shaped connecting bracket 21. The clamping surface of the clamping plate 22 is covered with a flexible pad made of polyurethane or silicone, which increases friction and prevents damage to the product surface.

[0039] Machine vision positioning system and collaborative control: An industrial camera (not shown in the figure) is fixedly mounted in the middle of the front crossbeam of the control frame 7 via an adjustable universal bracket. The camera is equipped with a ring LED light source. During installation, it is precisely calibrated so that its field of view can simultaneously cover the stacking platform 5 area (material picking station) on the machine base 1 below and the box 4 parking area (material unloading station) on the belt conveyor 3. The controller (using a PLC or industrial embedded computer, not shown in the figure) is electrically connected to the industrial camera, the servo drives of each motor, the electric push rod 13, and the belt conveyor 3.

[0040] The core workflow and precise positioning of this utility model are as follows:

[0041] Visual Recognition and Coordinate Acquisition: When the system starts or a loop begins, the controller first triggers the industrial camera to capture an image of the stacking platform 5. Through built-in image processing algorithms (such as template matching and contour extraction), the precise contour of the top-layer product is identified in real time, and its center coordinates (X1, Y1, Z1) in the mechanical coordinate system are calculated. Subsequently, the camera captures an image of the box placement area, identifies the opening position of the empty box 4, and calculates the coordinates (X2, Y2, Z2) of the target placement point of the box. This process converts visual information into absolute coordinate commands that can be executed by mechanical movement.

[0042] Precise material handling: Based on the product coordinates (X1, Y1), the controller drives the first motor 10, which, through the cooperation of the one-way lead screw 11 and the guide rod 14, precisely moves the entire moving seat 12 and the clamping mechanism below it along the X-axis to directly above the product (X1 position). Next, the electric push rod 13 is activated, driving the clamping seat 15 and clamping plate 22 to descend along the Z-axis to the preset material handling height. Then, the controller drives the second motor 16, causing the bidirectional lead screw 17 to rotate. Under the forced guidance of the linear guide rail 18, the two clamping plates 22 close synchronously and smoothly, accurately clamping the product.

[0043] Precise Transfer and Loading: After clamping, the electric push rod 13 lifts the product, and the first motor 10 drives the horizontal moving mechanism again to transport the product to directly above the box 4 (X2 position). Then, the electric push rod 13 descends again, feeding the product into the box 4 to the predetermined depth (Z2 position). At this time, the second motor 16 reverses, and the clamping plate 22 smoothly opens under the guidance of the linear guide rail 18, precisely releasing the product into the predetermined position within the box 4. The clamping mechanism then resets.

[0044] Circulation and Conveying: After the material is discharged, the controller can start the belt conveyor 3 to transport the filled box 4 away and send it into the next empty box. At the same time, the system can immediately start the next material feeding cycle.

[0045] Adaptability: For products of different sizes, only the product outline template and the preset gripper opening width (controlled by the number of rotations of the second motor 16) need to be updated in the control program, and the Z-axis height for picking and placing materials needs to be adjusted. The vision system can be recalibrated to adapt to the new working area. This adjustment does not require replacement of major mechanical components, demonstrating excellent flexibility.

[0046] It should be noted that the following terms in this specification, such as "upper," "lower," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "X-axis," "Y-axis," and "Z-axis," which indicate orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings. They are only for the purpose of facilitating the explanation of the present invention and simplifying the description, and do not imply that the device or component involved must have the specific orientation, or be constructed and operated in a specific orientation. Therefore, the above-mentioned orientation or positional relationship terms should not be understood or interpreted as limitations on the present invention.

[0047] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A fully automatic cartoning machine, characterized in that: It includes a machine base, a stacking platform located at one end of the machine base, a conveying mechanism located at the other end of the machine base, and a control frame, which is fixed above the machine base by multiple support columns; A horizontal moving mechanism, mounted on the control frame, is used to provide drive in the X-axis direction; A lifting mechanism is mounted on the horizontal moving mechanism to provide drive in the Y-axis direction; A gripping mechanism is provided at the output end of the lifting mechanism to provide drive in the Z-axis direction and perform product gripping and release. And a machine vision positioning system, including an industrial camera fixed on a control frame and a controller electrically connected to each part; The field of view of the industrial camera covers the stacking platform and the box placement area; The controller is configured to control the horizontal moving mechanism, lifting mechanism and gripping mechanism to complete automatic pick-and-place operations based on the product and box coordinates identified by the industrial camera.

2. The fully automatic cartoning machine according to claim 1, characterized in that: A mounting plate is fixed to one side wall of the control frame, and a first motor is fixed on the mounting plate. A rectangular through slot is provided on the top wall of the control frame.

3. The fully automatic cartoning machine according to claim 2, characterized in that: The horizontal moving mechanism includes: a one-way lead screw driven by the first motor; at least one guide rod arranged parallel to the one-way lead screw; and a moving seat that is screwed to the one-way lead screw via a lead screw nut and slidably engaged with the guide rod via a linear bearing.

4. The fully automatic cartoning machine according to claim 3, characterized in that: The lifting mechanism is an electric push rod, whose cylinder is fixed on the movable seat and passes through the rectangular through slot; the piston rod extends vertically downward and the clamping mechanism is fixed at its bottom end.

5. The fully automatic cartoning machine according to claim 1, characterized in that: The clamping mechanism includes: a clamping seat fixed to the output end of the lifting mechanism; a bidirectional lead screw driven by a second motor and having oppositely oriented threads at both ends, the bidirectional lead screw being supported on the clamping seat by bearings; two parallel linear guide rails fixed to the clamping seat and distributed on both sides of the bidirectional lead screw; two moving blocks respectively screwed onto the threads at both ends of the bidirectional lead screw; four sliders slidingly engaged with the linear guide rails and symmetrically distributed on the two linear guide rails; and each moving block being fixedly connected to two corresponding sliders on the left and right sides; and two clamping plates, each clamping plate being fixed to the bottom of one of the moving blocks by a connecting bracket.

6. The fully automatic cartoning machine according to claim 5, characterized in that: The clamping surface of the clamping plate is covered with a flexible pad.

7. The fully automatic cartoning machine according to claim 1, characterized in that: The conveying mechanism includes a conveyor platform, and a belt conveyor is installed in the platform body.

8. The fully automatic cartoning machine according to claim 1, characterized in that: The industrial camera is equipped with a ring LED light source, and the controller is a PLC or industrial embedded computer, which can be further electrically connected to the conveying mechanism.

Images