Method for automatically creasing a folding box with inserted packaging

Abstract

Method for automatically creasing a folding box (20) with inserted packaging (56), wherein the grooving of the side walls (22, 24, 26) of the folding box (20) is carried out by means of a grooving station (1) which comprises a grooving tool (10) with a rotatably mounted grooving roller (12) for grooving a flat workpiece and a rotatably mounted counter-pressure roller (14) which are held on one side on a common holder (16), wherein the distance between the two rollers (12, 14) is variable, wherein the grooving tool (10) is attached to a motion system for three-dimensional movability, and the following steps are carried out: a) Providing the folding box (20) open at the top in a vertical direction with the packaged goods (56) inserted, b) Determining the dimensions of the folding box (20) and the filling height of the packaged goods (56), c) Grooving of the side walls (22, 24, 26) of the folding box (20), wherein a first side wall is grooved at one of the first groove heights (30) assigned to the filling height determined in step b), characterized by that the counter-pressure roller (14) is mounted parallel to the creasing roller (12), that the counter-pressure roller (14) and the groove roller (12) are movable relative to each other to adjust a mutual distance, and that during the creasing process, when the creasing tool (10) reaches a vertical edge of the folding box (20), the roller located outside the folding box (20) is pivoted by 90° around the roller located inside the folding box (20), changing the distance between the creasing roller (12) and the counter-pressure roller (14).

Description

Field of invention

[0001] The invention relates to a method for automatically creasing a folding box with the contents inserted. State of the art

[0002] Millions of folding crates are packed with goods and shipped daily in Germany and other countries. Often, these crates are oversized. To prevent potential damage during transport, the empty spaces within the crates are regularly filled with packing material such as bubble wrap or paper. This incurs additional costs for the sender, which the end customer typically disposes of immediately upon receiving the package. Furthermore, shipping costs in many countries are calculated based on the weight and volume of the parcel, creating a strong incentive for packaging and shipping logistics companies to use crates whose volume is appropriately sized for the contents.

[0003] To achieve this, folding crates of various formats and dimensions are used. Ideally, the volume of the folding crate is chosen to be as small as possible for each item being packed. Additionally, there are approaches to reducing the empty space within packed folding crates by minimizing the unused volume above the goods, which is limited by the lid flaps of the crate.

[0004] DE 10 2012 004 208 B4 discloses a method for automatically closing a folding box with its contents in a closing machine, in which the contents are placed into a folding box that is open at the top in the vertical direction and has several circumferential grooves (folding edges) pre-embossed at different heights. The folding box is then cut along its vertical edges up to a groove corresponding to the fill level of the contents, the side walls are folded along this groove, and the folding box is closed by means of the resulting lid flaps.

[0005] A disadvantage of the known method is that, with folding boxes that have pre-embossed grooves (included in the unfolded box blank before folding and packing), the height of the box can only be adjusted to a limited extent to the fill level of the goods being packaged. The fill level can vary considerably depending on the goods being packed, and it may be necessary to add packing material not only to the sides but also above the goods to prevent them from shifting inside the oversized box.

[0006] From EP 3 284 687 A1, a method for adapting the volume of a folding box to the volume of the goods being packaged is known, in which not the height, but the depth of the folding box is adapted to that of the goods being packaged. For this purpose, a folding box is pre-folded so that a base and three side walls are formed. The goods being packaged are placed into the folding box, which is open on one side and at the top, and are pushed completely against the side wall opposite the open side. Then the base and the two side walls adjacent to the open side are scored, with the score being embossed directly next to the goods being packaged. In a next step, the base and side flaps defined in this way are folded together so that a folding box open at the top in the vertical direction is formed. Finally, a lid is placed on the folding box. How exactly the scoring process is carried out and which scoring tools are suitable for it are not disclosed.

[0007] An alternative method in which a folding box is scored only when packed with goods at a groove height corresponding to the fill level of the goods is disclosed in EP 2 185 424 B1.

[0008] The disadvantage here is that there is currently no creasing tool for crating a folding box with contents inserted, with which folding boxes of different dimensions can be quickly creasing one after the other and also neatly in the corner areas.

[0009] US Patent 2015 / 0119216 A1 discloses a generic method for automatically creasing a folding box with its contents. The creasing of the box's side walls is performed by a creasing station comprising a creasing tool with a rotatably mounted creasing roller and a rotatably mounted counter-pressure roller. The creasing roller has a profile on its circumference transverse to its longitudinal axis for embossing a groove; the counter-pressure roller has a profile on its circumference that is complementary to the profile of the creasing roller. One of the rollers is attached to a rigid arm and the other to a hinged arm, so that the distance between the roller and the counter-pressure roller can be adjusted by pivoting the hinged arm. The two arms are mounted on a common bracket, and the bracket is attached to a motion system to allow the creasing tool to move three-dimensionally.To groove a folding crate, a crate open at the top, containing the goods, is first prepared. The dimensions of the crate and the fill level of the goods are then determined. Next, the sides of the crate are grooved at a depth corresponding to the determined fill level. One side of the crate is clamped between the scoring roller and the counter-pressure roller, and the two rollers, without repeated opening and closing movements, traverse all sides of the crate, creating a single, continuous groove.

[0010] A disadvantage of the known method is that the corners of the folding box are pressed in during the creasing process. Furthermore, the adjustment of the distance between the two rollers is disadvantageously achieved by a pivoting movement of the movable roller. This leads, particularly with folding boxes that have thicker walls, to the profile of the creasing roller and the complementary counter-profile of the counter-pressure roller not being precisely aligned, and consequently, clean grooves cannot be pressed into the side walls of the folding box.

[0011] Various creasing tools are known for creasing different materials and workpieces. DE 2 061 973, for example, discloses a creasing tool for creasing flat workpieces made of cardboard, comprising a rotatably mounted creasing roller and a counter-pressure roller rotatably mounted parallel to the creasing roller, which have a fixed distance from each other and are each held on both sides.

[0012] A disadvantage of the known device is that the creasing tool is not suitable for creasing a folding box with already inserted packing material.

[0013] A creasing tool suitable for creasing a folding box with goods inserted is known from DE 25 50 284. The creasing tool comprises a set of press plates and press elements, with one press plate and one press element for each side wall of the folding box. To creasing the folding box to a crease height corresponding to the fill level of the goods inserted, the press plates are inserted horizontally along the inner sides of the folding box and come to rest flat on the surface of the goods. Each press plate has an outer edge for pressing a groove in conjunction with the associated press element, which is located on the outer side wall. By pressing the press elements against the stationary press plates, a groove is pressed into the side walls located between the press elements and press plates.

[0014] A disadvantage of this device is that the arrangement of the pressing plates is fixed to a frame that can only be moved vertically, meaning the device is only suitable for crating folding boxes of a specific size. To crate boxes of other dimensions, screws must be loosened and the arrangement of the pressing plates changed. Therefore, using this device to creasing folding boxes of different sizes is complicated and cumbersome. Furthermore, the pressing plates are designed to rest on the packaging material during the creasing process, so the creasing tool is primarily suitable for crating folding boxes containing flat items such as stacks of sheets or tiles.

[0015] An alternative creasing tool for creasing or beading thin sheets is disclosed in EP 0 585 613 B1. The creasing tool comprises a rotatably mounted creasing roller for creasing a flat workpiece and a counter-pressure roller rotatably mounted parallel to the creasing roller, which are mounted on one side of a common support so as to allow movement relative to each other in order to adjust a mutual distance.

[0016] A disadvantage of this known creasing tool is that it is mounted on a machine stand in such a way that the longitudinal axes of the creasing roller and the counter-pressure roller are horizontally aligned. This makes the tool unsuitable for creasing a folding box that is open at the top vertically and already contains goods. Instead, a flat workpiece must be moved between the creasing roller and the counter-pressure roller, which remain stationary during the creasing process.

[0017] From EP 2 684 802 A1, a scoring tool for scoring the side walls of a folding box with its contents inserted, at the fill level, is known. The scoring defines lid flaps that can be easily folded over to close the folding box. The scoring tool comprises four scoring rollers and a vertically movable support device with four counter-pressure plates, with one scoring roller and one counter-pressure plate assigned to each side wall of the folding box. One scoring roller is positioned on the outside of each side wall of the filled folding box. The support device is inserted into the folding box, with the four counter-pressure plates bearing against the inside of each side wall along its entire length.Each of the scoring rollers has a rotating cutting disc that cuts into the outside of the folding box side wall during the scoring process, while the counter-pressure plate provides counter-pressure on the opposite inside of the folding box side wall.

[0018] A disadvantage of this tool is that it scores the side walls. This scoring reduces the stackability of the boxes, as they are less able to withstand pressure from above. Furthermore, the sections of the side walls intended to serve as lid flaps can tear off if the scoring is too deep. In addition, the fixed size of the counter-pressure plates makes this device unsuitable for processing folding boxes of varying dimensions.

[0019] WO 2016 / 151310 A1 discloses a device for adjusting the volume of a folding box to the volume of its contents, comprising two creasing stations of analogous design. Each creasing station includes a creasing tool in which two creasing jaws are mounted horizontally on a common bracket for movement. The two jointly mounted creasing jaws are assigned to opposite corners of a folding box. Each creasing jaw has two corresponding gripping jaws with a right-angled outer and inner edge, between which the corner of a folding box can be clamped, so that a groove is created when sufficient pressure is applied.

[0020] A disadvantage of using this known device to groove a folding crate is that the crate must pass through two scoring stations to ensure a groove is formed in all side walls. Furthermore, the device is not suitable for grooving folding crates of varying dimensions. To achieve a circumferential groove in all four side walls of the crate with this known device, the width of each side wall must be at least equal to and at most twice the length of the outer or inner edges of the scoring jaws.

[0021] All known creasing tools and methods for creasing a folding box are not yet optimally developed. Task

[0022] It is therefore the object of the present invention to propose a method for automatically creasing a folding box with inserted goods, which allows for quick, neat creasing of the side walls of folding boxes of different dimensions without the corner areas of the folding box being pressed in during creasing. Description of the invention

[0023] The problem is solved in conjunction with the features of the preamble of claim 1 by the fact that the counter-pressure roller is mounted parallel to the creasing roller, that the counter-pressure roller and the creasing roller are movable relative to each other to adjust a mutual distance, and that during the creasing process, when the creasing tool reaches a vertical edge of the folding box, the roller arranged outside the folding box is pivoted by 90° about the roller arranged inside the folding box, thereby changing the distance between the creasing roller and the counter-pressure roller.

[0024] According to the invention, during the creasing process, when the creasing tool reaches a vertical edge of the folding box, the roller located outside the box is pivoted 90° around the roller located inside the box, thereby changing the distance between the creasing roller and the counter-pressure roller. For example, the distance is increased when pivoting between 0° and 45° and decreased again when pivoting between 45° and 90°. This allows for quick and neat creasing of the side walls of the folding box without the corner areas of the box being indented during creasing.

[0025] The movement system to which the creasing tool is attached for three-dimensional movement can be designed either as a robot arm or a rail system. An advantage of the present invention is that the creasing station allows the side walls of folding boxes of different sizes to be scored quickly and sequentially. The contour of the packaged goods is irrelevant for scoring the side walls using the creasing station. Because the creasing roller and the counter-pressure roller are only mounted on one side of a common bracket, while the opposite ends of the creasing roller and the counter-pressure roller are free, the creasing tool can be positioned on a side wall of a folding box in such a way that it can be clamped between the roller and the counter-pressure roller and scored. The distance between the creasing roller and the counter-pressure roller can be adjusted pneumatically or by motor.Furthermore, if required, one of the rollers can be actively driven by a drive mechanism. Preferably, the creasing roller is designed as a rotatable creasing shaft, which has a profile on its circumference transverse to its longitudinal axis for embossing a groove. Alternatively, the creasing roller can comprise a stationary shaft with a rotatable creasing wheel. The counter-pressure roller can optionally have a counter-profile on its circumference that is complementary to the profile or creasing wheel of the creasing roller.

[0026] In this process, a folding crate, open at the top and containing its contents, is first fed into the creasing station. To begin creasing, the creasing tool is positioned on one side of the crate, with the creasing roller aligned perpendicular to the bottom of the crate and the counter-pressure roller aligned perpendicular to the side of the crate. The side of the crate is then clamped between the creasing roller and the counter-pressure roller by reducing the distance between the two rollers. To create a groove in the side of the crate, the creasing tool then travels around the sides until it returns to its starting position, completing the entire process and creasing each side of the crate. Finally, the distance between the two rollers is increased, and the crate is released.For the creasing process, the creasing roller is preferably positioned on the inside of the folding crate and the counter-pressure roller on the outside, so that the side walls are creased on their inner side. This has the advantage that, after creasing and folding the resulting lid flaps, a clean edge is created on the outside of the folding crate. Due to the flexibility of the creasing station, the side walls can also be creased on their outer side if required, either alternatively or additionally.

[0027] Preferred embodiments of the invention are the subject of the dependent patent claims.

[0028] In one embodiment, the side wall opposite the first side wall is grooved at the first groove height, and the side walls adjacent to the first side wall are grooved at a second groove height, offset vertically from the first groove height by the wall thickness determined in step b). If all side walls of a folding box are grooved at the same groove height, restoring forces act on the lid flaps when they are folded in, causing them to unfold again after folding unless a force opposes this action. Grooving a pair of opposing side walls of a folding box at a different groove height than the adjacent side walls has the advantage of reducing the restoring forces acting on the lid flaps.Furthermore, grooving the adjacent side walls with a vertical offset of only one wall thickness ensures that the unused volume above the packaged goods does not become unnecessarily large due to grooving at two different heights.

[0029] Alternatively, it can be calculated from the fill height of the packaged goods determined in step b) whether, if the first side wall and the side wall opposite the first side wall are scored at the first scoring height, a subsequent cutting of the folding box at its vertical edges up to the first scoring height and folding of the first side wall and the side wall opposite the first side wall at the first scoring height will lead to an overlap of the first side wall and the side wall opposite the first side wall, or not, and in the case of no calculated overlap, the side wall opposite the first side wall is scored at the first scoring height, and in the case of a calculated overlap, the side wall opposite the first side wall is scored at a second scoring height, which is offset vertically by the wall thickness determined in step b).In this way, the restoring forces acting on the lid flaps when folding are further minimized.

[0030] To further minimize the restoring forces acting on the lid flaps during folding, it can additionally be calculated whether, if the side walls adjacent to the first side wall are scored at a third scoring height (different from the first and second scoring heights and offset vertically from them by the wall thickness determined in step b), a subsequent cutting of the folding box at its vertical edges up to the first scoring height and folding of the side walls adjacent to the first side wall at the third scoring height will result in an overlap of the side walls adjacent to the first side wall, and, in the case of no calculated overlap, the side walls adjacent to the first side wall will be scored at the third scoring height, and, in the case of a calculated overlap, one side wall adjacent to the first side wall will be scored at the third scoring height and the other side wall adjacent to the first side wall at a fourth scoring height.which is not equal to the first, second and third groove height and is offset from these in the vertical direction by the wall thickness determined in step b).

[0031] According to the invention, the grooving of the side walls of the folding box is carried out by means of a grooving station comprising a grooving tool with a rotatably mounted grooving roller for grooving a flat workpiece and a counter-pressure roller rotatably mounted parallel to the grooving roller. These counter-pressure rollers are mounted on one side of a common bracket so that they can be moved relative to each other to adjust the distance between them. The grooving tool is attached to a motion system for three-dimensional movement. While the grooving of the side walls of the folding box can be carried out at different groove heights, offset by one wall thickness each time, using conventional grooving tools, this new method offers a different solution.However, it is particularly advantageous if the creasing is carried out using a creasing station as described, since this is suitable for quickly creasing several vertically open folding boxes, which may have different dimensions and may be packed with different goods, one after the other.

[0032] It is further preferred that, based on the wall thickness of the folding box's side walls determined in step b), a suitable distance between the creasing roller and the counter-pressure roller is determined for creasing the side walls. Depending on the wall thickness, more or less force must be applied to creasing the side walls of the folding box. By adjusting the distance between the two rollers according to the wall thickness, it is prevented that the groove is pressed too deeply and that the resulting lid fold potentially tears. Furthermore, it avoids the need to repeatedly pass the crating tool around the folding box to press a groove into each side wall.

[0033] It is particularly advantageous if the folding crate is held in position by a holding device during the creasing process. This prevents the crate from slipping during creasing. The holding device can, for example, be designed as a vacuum suction cup.

[0034] Further details and advantages of the invention will become apparent from the following specific description and the drawings. Brief description of the drawings

[0035] They show: Fig. 1: Perspective view of a creasing tool for a creasing station for the automatic creasing of a folding box with inserted packaging; Fig. 2: Perspective view of an alternative embodiment of a grooving tool; Fig. 3: Positioning the grooving tool according to Fig. 1 on one side of a folding box; Fig. 4: Perspective view of the grooving process with a grooving tool as well as Fig. 5: Schematic top view of a creasing process when the creasing tool reaches a vertical edge of the folding box. Description of preferred embodiments

[0036] Identical reference symbols in the figures indicate identical or analogous elements.

[0037] Fig. Figure 1 shows an embodiment of a creasing tool 10 for a creasing station for automatically creasing a folding box with its contents. The creasing roller 12 and the counter-pressure roller 14 are mounted on one side of a common holder 16, with the distance between the two rollers 12, 14 being adjustable. The opposite ends of the creasing roller 12 and the counter-pressure roller 14 are free, allowing a side wall of a folding box to be clamped and creased between the rollers 12, 14. In the embodiment shown, the creasing roller 12 is designed as a rotatable creasing shaft, which has a profile on its circumference transverse to its longitudinal axis for embossing a groove in the form of an embossing ring 121. Alternatively, the creasing roller 12 can comprise a stationary axle with a rotatable creasing wheel (not shown here). The counter-pressure roller 14 can have a counter-profile on its circumference that is complementary to the profile or the groove wheel of the groove roller (not shown here).

[0038] Furthermore, one of the rollers 12, 14 can be actively driven by means of a drive 18, as shown in Fig. Figure 2 shows an alternative embodiment of a creasing tool for a creasing station for automatically creasing a folding box with inserted packaging. The drive 18 can be, as in Fig. 2 shown, at the free end or, as in Fig. As shown in Figure 4, the counter-pressure roller 14 is arranged at the supported end of the creasing roller 12. It is also conceivable to additionally or alternatively drive the counter-pressure roller 14 by means of a drive 18 (not shown here).

[0039] Fig. Figure 3 shows the positioning of the grooving tool 10. Fig. 1 on a side wall 22 of a folding box 20. Using an optical measuring device 60, the fill height of the packaged goods 56 placed in a folding box 20, which is open at the top in a vertical direction, and the dimensions of the folding box 20 are determined. Then, the creasing tool 10 is positioned on a side wall 22 of the folding box 20 using a robot arm or a rail system (not shown here) such that the creasing roller 12 on one side wall 22 and the counter-pressure roller 14 on the other side wall 22 are aligned perpendicular to the bottom of the folding box 20. By reducing the distance between the two rollers 12, 14, the side wall 22 is clamped between the creasing roller 12 and the counter-pressure roller 14. Preferably, the creasing roller 12 is positioned on the inside of the folding box 20 and the counter-pressure roller 14 on the outside, so that the side walls are creased on their inside.

[0040] Alternatively, the creasing roller 12 can be positioned on the outside and the counter-pressure roller 14 on the inside of the folding box 20, as shown in Fig. 4 shown. Fig. Figure 4 shows the grooving of a side wall 22, wherein the grooving tool 10 travels along the side wall 22 at a first groove height corresponding to the fill level of the packaged goods 56. In the embodiment shown here, the grooving roller 12 is driven by a drive 18 arranged at the supported end of the grooving roller 12. Advantageously, the folding box 20 is held in position during the grooving process by holding means (not shown here).

[0041] Fig.Figure 5 shows the creasing process according to the invention in the corner area of ​​the folding box 20. When the two rollers 12, 14 of the creasing tool 10 reach a vertical edge of the folding box 20 where two side walls 22, 24 meet, the roller 14 located outside the folding box 20 is pivoted by 90° about the roller 12 located inside the folding box 20, thereby changing the distance between the creasing roller 12 and the counter-pressure roller 14 so that the corner areas of the folding box 20 are not pressed in during creasing. The distance can be increased during the pivoting motion between 0° and 45° and decreased again between 45° and 90°.

[0042] Naturally, the embodiments discussed in the detailed description and shown in the figures represent only illustrative examples of the present invention. In light of this disclosure, a wide range of possible variations is available to the person skilled in the art. Reference symbol list 1 Grooving station 10 Grooving tools 12 Grooving roller 121 embossing ring 14 Counter-pressure roller 16 bracket 18 Drive 20 folding boxes 22, 24, 26 side walls of 20 30 first groove height 56 packages 60 optical measuring device

Claims

[1] Method for automatically creasing a folding box (20) with packaged goods (56) inserted, wherein the grooving of the side walls (22, 24, 26) of the folding box (20) is carried out by means of a grooving station (1) which comprises a grooving tool (10) with a rotatably mounted grooving roller (12) for grooving a flat workpiece and a rotatably mounted counter-pressure roller (14) which are held on one side on a common holder (16), wherein the distance between the two rollers (12, 14) is variable, wherein the grooving tool (10) is attached to a motion system for three-dimensional movability, and the following steps are carried out: a) Providing the folding box (20) open at the top in a vertical direction with the packaged goods (56) inserted, b) Determining the dimensions of the folding box (20) and the filling height of the packaged goods (56), c) Grooving of the side walls (22, 24, 26) of the folding box (20), wherein a first side wall is grooved at one of the first groove heights (30) assigned to the filling height determined in step b), characterized by , that the counter-pressure roller (14) is mounted parallel to the creasing roller (12), that the counter-pressure roller (14) and the groove roller (12) are movable relative to each other to adjust a mutual distance, and that during the creasing process, when the creasing tool (10) reaches a vertical edge of the folding box (20), the roller located outside the folding box (20) is pivoted by 90° around the roller located inside the folding box (20), changing the distance between the creasing roller (12) and the counter-pressure roller (14). [2] Method according to claim 1, characterized by, that in step b) the wall thickness of the side walls (22, 24, 26) is determined from the external dimensions of the folding box (20) measured by means of an optical measuring device (60) by comparison with data stored in a data storage device. [3] Method according to claim 2, characterized by , that the side wall opposite the first side wall is grooved at the first groove height (30) and the side walls adjacent to the first side wall are grooved at a second groove height, which is offset vertically by the wall thickness determined in step b) to the first groove height (30). [4] Method according to claim 2, characterized by, that from the fill height of the packaged goods (56) determined in step b), it is calculated whether, when the first side wall and the side wall opposite the first side wall are scored at the first scoring height (30), a subsequent cutting of the folding box (20) at its vertical edges up to the first scoring height (30) and folding of the first side wall and the side wall opposite the first side wall at the first scoring height (30) will lead to an overlap of the first side wall and the side wall opposite the first side wall or not, and in the case of no calculated overlap, the side wall opposite the first side wall is scored at the first scoring height (30), and in the case of a calculated overlap, the side wall opposite the first side wall is scored at a second scoring height, which is offset vertically by the wall thickness determined in step b) to the first scoring height (30). [5] Method according to claim 4, characterized by, that it is calculated whether, when the side walls adjacent to the first side wall are scored at a third scoring height, which is different from the first (30) and the second scoring height and which is offset vertically from these by the wall thickness determined in step b), a subsequent cutting of the folding box at its vertical edges up to the first scoring height (30) and folding of the side walls adjacent to the first side wall at the third scoring height will lead to an overlap of the side walls adjacent to the first side wall or not, and in the case of no calculated overlap, the side walls adjacent to the first side wall are scored at the third scoring height, and in the case of a calculated overlap, one side wall adjacent to the first side wall is scored at the third scoring height and the other side wall adjacent to the first side wall is scored at a fourth scoring height, which is different from the first (30),The second and third groove height is offset from these in the vertical direction by the wall thickness determined in step b). [6] Method according to any one of claims 2 to 5, characterized by , that based on the wall thickness of the side walls (22, 24, 26) of the folding box (20) determined in step b), a suitable distance between the creasing roller (12) and the counter-pressure roller (14) for creasing the side walls (22, 24, 26) is determined. [7] Method according to any of the preceding claims, characterized by , that the folding box (20) is held in position by holding means during the creasing process.

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