Arrangement and method for filling cavities in transport containers with paper cushioning units

Abstract

The present invention relates to an arrangement for filling cavities in transport containers with paper cushioning units, comprising a transfer device that is movable between a first position corresponding to a provision area for cushioning material and a second position for placing cushioning material or a cushioning unit made of the cushioning material in a cavity of a transport container, wherein the transfer device has a needle gripper.

Description

[0001] The invention relates to an arrangement and a method for filling cavities in transport containers with cushioning units made of paper.

[0002] A packaging system for dispensing cushioning material based on cavity volume determination is described in EP 1 556 278 B1. A scanner is provided on a conveyor belt for transport containers. This scanner has sensors for detecting the height and width of a transport container, as well as a contour sensor for detecting the goods positioned within the container. Control logic processes the information acquired by the sensors and uses this information to determine the required amount of cushioning material to fill the remaining space in the transport container. The quantity of cushioning material to be dispensed is determined according to a desired cavity filling density, which can be increased or decreased from an arbitrary standard value by user input. EP 1 556 278 B1 suggests kraft paper or plastic peanuts as suitable cushioning materials.The cushioning material should flow from a cushioning dispensing device in the calculated quantity either directly into the transport container, be introduced by a person, or be placed inside. Specifying an idealized void fill density has proven problematic, especially for untrained packing personnel, as the input is unintuitive and packing personnel often reduce or further compress the amount to be introduced, frequently resulting in a fill that does not meet the calculated target. For environmental reasons, the use of cushioning materials made of plastic should be avoided.

[0003] US patent 11,053,041 B2 describes an automatic packing device for filling shipping cartons with cushioning elements. In this device, several tubular, elongated cushioning elements are provided to a magazine, and shipping cartons are moved on a conveyor belt. Several grippers are mounted on a frame that is movable both laterally and vertically relative to the conveyor belt. The grippers include jaws for grasping the longitudinal ends of the cushioning elements. Dispensing means are provided to push the cushioning elements downwards from the grippers into a shipping container. Another system for dispensing cushioning elements is disclosed in EP 1,015,240 B1, in which prepared cushioning elements are dispensed from a dispensing container into a shipping container via two downward-swinging gate sections, with or without a plunger. A variety of suitable dispensing containers are provided for different shipping containers and goods.The packing device and cushioning system are very large, slow, and require precise adjustment of the available cushioning elements to the individual shipping cartons and the goods they contain. Voids whose shape and position do not coincidentally correspond to the predetermined position of the available cushioning element cannot be reliably filled.

[0004] WO 2019 / 174800 A1 describes a device for moving a large number of cushioning materials into a transport container as quickly as possible. For this purpose, the device is equipped with an ejection mechanism that propels the cushioning materials along a ballistic trajectory towards the waiting transport containers. Experience has shown that this method is unreliable and therefore leads to both high reject rates and potentially inadequately cushioned transport containers.

[0005] WO 1998 021 101 A1 describes an automatic cushioning manufacturing and filling system for providing cushioning pads for filling transport containers. The cushioning pads are to be produced taking into account the packing requirements of a transport container of a predetermined length. A receiving / depositing unit for the cushioning pads has a hand that is movably supported by a pair of pneumatic cylinders. The hand can have multiple vacuum ports to grip a pad and hold it during movement from a staging area to a filling point. The hand can be moved horizontally and vertically and rotated.

[0006] The object of the invention is to overcome the disadvantages of the prior art, in particular to provide an arrangement and a corresponding method that ensures rapid and / or reliable filling adapted to the requirements of individual transport containers, preferably partially filled with goods.

[0007] This problem is solved by the subject matter of independent claims.

[0008] This document describes an arrangement for filling voids in transport containers with paper cushioning units. A paper cushioning unit, simply put, a paper cushion, or more generally, a three-dimensional packaging product, is manufactured from a single-web material, such as a single- or multi-ply paper web. The creation or manufacture of a three-dimensional packaging product refers specifically to transforming a web-like material into a state with a greater extent in the direction of the material's thickness compared to the original material. For ecological reasons, recycled paper is increasingly used as the paper material. However, due to its inhomogeneity, recycled paper is difficult to process, especially when the three-dimensional packaging product needs to be uniform, simple, and economical to manufacture.The starting material web can be made of paper, such as recycled paper, in particular waste paper, and / or 100% recyclable paper, which may be produced without chemical additives. Recycled paper is, in particular, paper materials with a low proportion (less than 50%) of virgin fiber paper. For example, paper materials containing 70% to 100% waste paper are used. The recycled paper within the meaning of this invention can be paper material that has a tensile strength index along the machine direction of at most 90 Nm / g, preferably a tensile strength of 15 Nm / g to 60 Nm / g, and a tensile strength index transverse to the machine direction of at most 60 Nm / g, preferably a tensile strength of 5 Nm / g to 40 Nm / g. The tensile strength and the tensile strength index can be determined according to DIN EN ISO 1924-2 or DIN EN ISO 1924-3.Alternatively, or in addition, the properties of recycled or waste paper can be characterized by its burst resistance. A material in this sense is recycled paper with a burst index of no more than 3.0 kPa*m^2 / g, preferably with a burst index of 0.8 kPa*m^2 / g to 2.5 kPa*m^2 / g. The standard DIN EN ISO 2758 is used to determine the burst index. Furthermore, the packaging material has a basis weight of, in particular, 40 g / m² to a maximum of 140 g / m². The starting material can be in the form of a roll of material or a zigzag-folded stack of packaging material, also known as a leporello stack.For example, the paper cushion is a strand-shaped cushioning material with two compression cavities extending in the longitudinal direction of the strand and a central deformation band connecting the compression cavities, which is deformed and may be, for example, embossed, punched, perforated or the like.

[0009] The arrangement according to the invention can be configured as a packaging material processing station, also called a paper cushion processing station, and can form a pre-formed paper cushion or a paper cushion from a strip-shaped starting material and transfer the paper cushion into a transport container, in particular by inserting it. This allows packaging material to be processed, especially automatically, paper cushions to be produced, and produced paper cushions to be inserted into cavities of transport containers, which are, for example, filled with goods being shipped. Furthermore, transport containers for receiving and cushioning goods being shipped can be lined with paper cushions.

[0010] The arrangement according to the invention comprises a transfer device that is movable between a first position corresponding to a provision area for cushioning material and a second position for placing cushioning material or a cushioning unit made of the cushioning material in a cavity of a transport container. The transfer device can, for example, be designed as a robot or include a robot. A robot can be understood as an autonomous machine or a handling device designed to perform tasks or functions that mimic or replace human actions. The robot may have the ability to interact with its environment, process information, and perform actions without direct human control or intervention.The robot can be programmable, specifically programmed to perform certain tasks or functions autonomously or under the control of a human operator. Various types of robots can be used, ranging from physical machines with mechanical bodies and actuators to virtual agents that exist only in software. The robot can be equipped with sensors to collect data about its environment, such as cameras, microphones, or other specialized sensors, which can serve as the basis for decision-making processes. Furthermore, the robot can be equipped with algorithms, particularly artificial intelligence, that enable it to analyze complex data, learn from experience, and adapt its behavior accordingly.

[0011] According to a first aspect of the present invention, the transfer device includes a needle gripper. The needle gripper has proven particularly advantageous for paper cushions, which are generally made of a thin, flexible material. Furthermore, the paper cushions can be flexible due to their low inherent rigidity, which makes gripping them difficult. The needle gripper can be designed to pierce the paper cushions, in particular to interlock with them, thus enabling secure gripping and, above all, subsequent movement and / or handling of the paper cushions. Because the paper material of the paper cushions is generally very thin, the needles of the needle gripper can be very short. Therefore, the paper cushion can be securely gripped and handled by means of the needle gripper.For example, the needle gripper initially exerts a certain amount of pressure on the paper cushion to compress it to a certain degree. This minimizes the cushion's movement when the needles are driven in, thus increasing the reliability of the grip. Since the paper always moves at least slightly when the needles are driven in, they are driven into pre-compacted sections of the cushion strand, such as a central area where several layers of paper are pressed relatively tightly together. This allows the needles to penetrate multiple layers of paper that yield very little due to their compaction. Therefore, the needle gripper achieves a very secure grip on the cushion.

[0012] In an exemplary embodiment of the arrangement according to the invention, the needle gripper has at least two, preferably a plurality, needles and a gripping state in which the needles are extended, as well as a resting state in which the needles are retracted. By retracting the needles in the resting state, the needle gripper can perform a stripping function that facilitates the release or dispensing of the paper pad grasped by the needle gripper. Furthermore, the risk of injury to any operators is reduced when the needles are not extended, and in particular not protruding, in the resting state.

[0013] In a further unprecedented embodiment of the present invention, the direction of movement of one needle during extension and retraction, particularly with respect to a housing of the needle gripper, is oriented transversely to the direction of movement of another needle during extension and retraction. In an exemplary further development, the needles, preferably their directions of movement, are arranged and / or aligned with respect to one another such that the needles shear past each other. With a plurality of needles present, at least two shear directly past each other. For example, the shearing needles can cross each other. This causes the crossing needles to interlock with the paper material of the paper cushion, thereby enabling it to be gripped and held even more reliably. Alternatively, the needles can also move away from each other, particularly to cover the largest possible area.

[0014] According to a further exemplary embodiment of the packaging material processing station according to the invention, when the needles assume their resting state, they retract, in particular, into a housing or a receptacle of the needle gripper that carries and / or supports the needles, such that a paper cushion gripped by the needles is stripped off to release the paper cushion. For example, the housing or receptacle can have a stripping surface facing the paper cushion, in particular a flat surface, with respect to which the needles are recessed in the resting state and / or project in the gripping state.

[0015] In a further exemplary embodiment of the present invention, the arrangement comprises a cushioning material forming device, which may also be referred to as a paper cushion generating device or paper cushion supply device, and which is designed and configured to form a strand-shaped cushioning material with two compressible cavities extending in the longitudinal direction of the strand and a central deformation band connecting the compressible cavities. In other words, the cushioning material forming device is a device for generating a three-dimensional paper cushion or, more generally, a packaging product, such as a cushioning product, from a web-shaped starting material, such as a single- or multi-layer paper web.The creation of a three-dimensional packaging product refers in particular to the transformation of a web-shaped starting material into a state with a greater extent in the direction of the starting material's thickness compared to the original material. According to an exemplary embodiment, the shape of the gripping side of the needle gripper facing the cushioning material is adapted to the formed cushioning material. The needle gripper can have a central gripping section for engaging the deformation strip and two lateral contact sections, set back from the gripping section, for the compression cavities.

[0016] According to a further aspect of the present invention, which can be combined with the preceding aspects and exemplary embodiments, an arrangement for filling cavities in transport containers with cushioning units made of paper is provided.

[0017] A paper cushioning unit, simply put, a paper cushion, or more generally a three-dimensional packaging product, is manufactured from a web-like starting material, such as a single- or multi-ply paper web. The creation or manufacture of a three-dimensional packaging product refers specifically to transforming a web-like starting material into a state with a greater extent in the direction of the starting material's thickness compared to the original material. For ecological reasons, recycled paper is increasingly used as the paper material; however, due to its inhomogeneity, it is difficult to form, especially if the three-dimensional packaging product needs to be uniform and manufactured as simply and economically as possible.The starting material web can be made of paper, such as recycled paper, in particular waste paper, and / or 100% recyclable paper, which may be produced without chemical additives. Recycled paper is, in particular, paper materials with a low proportion (less than 50%) of virgin fiber paper. For example, paper materials containing 70% to 100% waste paper are used. The recycled paper within the meaning of this invention can be paper material that has a tensile strength index along the machine direction of at most 90 Nm / g, preferably a tensile strength of 15 Nm / g to 60 Nm / g, and a tensile strength index transverse to the machine direction of at most 60 Nm / g, preferably a tensile strength of 5 Nm / g to 40 Nm / g. The tensile strength and the tensile strength index can be determined according to DIN EN ISO 1924-2 or DIN EN ISO 1924-3.Alternatively, or in addition, the properties of recycled or waste paper can be characterized by its burst resistance. A material in this sense is recycled paper with a burst index of no more than 3.0 kPa*m^2 / g, preferably with a burst index of 0.8 kPa*m^2 / g to 2.5 kPa*m^2 / g. The standard DIN EN ISO 2758 is used to determine the burst index. Furthermore, the packaging material has a basis weight of, in particular, 40 g / m² to a maximum of 140 g / m². The starting material can be in the form of a roll of material or a zigzag-folded stack of packaging material, also known as a leporello stack.For example, the paper cushion is a strand-shaped cushioning material with two compression cavities extending in the longitudinal direction of the strand and a central deformation band connecting the compression cavities, which is deformed and may be, for example, embossed, punched, perforated or the like.

[0018] The arrangement according to the invention can be configured as a packaging material processing station, also called a paper cushion processing station, and can form a pre-formed paper cushion or a paper cushion from a web-like starting material and transfer the paper cushion into a transport container, in particular by inserting it. This allows packaging material to be processed, especially automatically, paper cushions to be produced, and produced paper cushions to be inserted into cavities of transport containers, which are, for example, filled with goods being shipped. Furthermore, transport containers for receiving and cushioning goods being shipped can be lined with paper cushions.

[0019] The arrangement according to the invention comprises a transfer device that is movable between a first position corresponding to a provision area for cushioning material and a second position for placing cushioning material or a cushioning unit made of the cushioning material in a cavity of a transport container. The transfer device can, for example, be designed as a robot or include a robot. A robot can be understood as an autonomous machine or a handling device designed to perform tasks or functions that mimic or replace human actions. The robot may have the ability to interact with its environment, process information, and perform actions without direct human control or intervention.The robot can be programmable, specifically programmed to perform certain tasks or functions autonomously or under the control of a human operator. Various types of robots can be used, ranging from physical machines with mechanical bodies and actuators to virtual agents that exist only in software. The robot can be equipped with sensors to collect data about its environment, such as cameras, microphones, or other specialized sensors, which can serve as the basis for decision-making processes. Furthermore, the robot can be equipped with algorithms, particularly artificial intelligence, that enable it to analyze complex data, learn from experience, and adapt its behavior accordingly.

[0020] According to a further aspect of the present invention, the transfer device comprises a gripper with at least two prongs for grasping the cushioning material or the cushioning unit, wherein the gripper has a passive state with the prongs separated from each other and an active state with the prongs approaching each other. In other words, the prongs can be movable between an active position defining the active state and a passive position defining the passive state. For example, the prongs can wedge or hook the cushioning material or the cushioning unit between themselves.

[0021] In a further exemplary embodiment of the present invention, the transfer device, particularly with the gripper, is translationally movable in at least two, preferably three, directions. Thus, the transfer device, and especially the gripper, is particularly flexible and can perform complex movements for gripping, transferring, and ultimately filling the transport container. According to an exemplary further development, the arrangement includes a guide for moving the gripper with the transfer device in at least one direction, preferably in two or three directions. This allows for precise and linear movement of the gripper.

[0022] In a further exemplary embodiment of the arrangement according to the invention, the prongs are at least partially needle-shaped in order to penetrate the cushioning material in the active state for gripping. The gripper can, for example, be designed as a needle gripper. In an exemplary further development, the prongs comprise at least two prongs movable relative to each other along their needle extension direction from the passive state to the active state. For example, the gripper is designed and configured to cooperate with a plastically deformed, in particular die-cut perforated and / or roll-embossed, deformation area of ​​the cushioning material. It has been found that the paper cushioning products to be processed are, firstly, flexible and, secondly, exhibit varying degrees of flexibility in different sections of the paper cushion.The gripper can be adapted to these different characteristics of the paper cushion. For example, the paper cushions have a central deformation band, which is stiffer, as well as lateral, voluminous crumple cavities that are more flexible or yielding.

[0023] According to a further exemplary embodiment of the arrangement according to the invention, the at least two prongs are designed with clamping jaws for force-fit gripping, in particular clamping, of the padding material between opposing clamping surfaces of the clamping jaws in the active state. For example, the gripper can be designed as a finger gripper. For example, the prongs clamp the padding material transversely to the longitudinal extent of the padding at the lateral sides, in particular in the crumple zones.

[0024] In another exemplary embodiment, the gripper or needle gripper for winding the cushioning material or cushioning unit into a cushioning spiral is rotatable about a spindle axis, which preferably forms an axis of symmetry with respect to the tines. For example, the tines of the gripper or needle gripper as a whole can be mounted to rotate, particularly with respect to its axis of symmetry, so that when the gripper or needle gripper rotates, the paper cushioning unit or paper cushioning strand rotates around itself to form a so-called cushioning spiral. After winding, the cushioning spiral can constitute an independent, final cushioning product, which, in particular by gluing the winding end to the outer winding layer, forms a fixed, rigid unit that can thus be used for cushioning products or for filling transport containers.According to one exemplary embodiment, the arrangement further includes a guide device to support the formation of the cushion spiral. It has been found that during winding, the paper cushioning material being wound can shift, particularly in the direction of the spindle axis and / or in the direction of gravity. This impairs the formation of the paper cushion spiral, and especially its shape. According to another exemplary embodiment, the guide device is assigned to the gripper or needle gripper in such a way that the guide device directs the forming cushion spiral transversely, and in particular perpendicularly, to the spindle axis. For example, the guide device can be designed as a kind of flat disc or support in the direction of gravity below the forming cushion spiral.This makes it possible to reliably form the cushion screw even when the gripper or needle gripper is aligned so that the spindle axis is oriented perpendicular to the direction of gravity.

[0025] In an exemplary further development of the arrangement according to the invention, the transfer device is designed and configured to insert the gripper into the cavity of the transport container and to initiate the winding of the cushioning material into a cushioning spiral within the cavity. In other words, the cushioning spiral is only formed at the final point of use. This can offer the advantage that the cushioning spiral automatically adapts its shape to the available space during the winding process. Thus, a cushioning spiral can be formed that deviates significantly from a circular cross-sectional shape and is, for example, considerably more oval.

[0026] In a further exemplary embodiment of the present invention, the arrangement includes a separating device for singulating a cushioning unit from the cushioning material, which is held in an active state, in particular by the gripper or needle gripper. The separating device can, for example, be rigidly arranged with respect to the arrangement or be movable. The separating device and the gripper or needle gripper can be coordinated with each other or arranged in relation to each other such that the separating device can reliably access the cushioning material to singulate a paper cushioning unit from it.

[0027] According to a further exemplary embodiment of the present invention, the transfer device is designed to grasp the cushioning material or the cushioning unit at one longitudinal end and / or to grasp the cushioning unit in the middle. Depending on the available or to-be-filled cushioning volume or space, it may be advantageous to grasp the cushioning unit either at one longitudinal end or approximately in the middle. The gripping action also affects the potential formation of a cushion coil.

[0028] According to an exemplary embodiment of the arrangement according to the invention, the transfer device, in particular the gripper or needle gripper, comprises at least one sensor, such as a position, force, and / or torque sensor. For example, the transfer device can be designed to initiate a holding and / or safety state of the gripper or needle gripper when a predetermined measurement signal from the sensor, such as a maximum torque threshold, occurs. For example, the transfer device can be equipped with software or a controller.For example, when the maximum torque threshold is detected, particularly during the formation of a cushion spiral, the control signal for cushion winding can be overridden and a control signal can be issued to enter a holding and / or safety state, thereby aborting the cushion winding process, especially to prevent damage. This allows, for instance, detection if the gripper or needle gripper encounters excessive resistance during cushion winding and is therefore in an incorrect position or condition.

[0029] In a further exemplary embodiment of the arrangement according to the invention, the arrangement comprises at least one folding unit with at least one folding counter-support, in particular two or three folding counter-supports arranged at a uniform or arbitrarily chosen distance from one another. The folding unit can serve to deform a paper cushion strand or even a paper cushion unit, in particular to compress, coil, or use it to form a cushion spiral. The transfer device can be designed and configured to move the cushioning material relative to the at least one folding counter-support by means of the gripper or needle gripper. The folding counter-support can also serve as a stop or support, for example to limit lateral spreading, in particular expansion, of the cushion spiral.For example, the transfer device may be designed or configured to move the gripper or needle gripper against at least one of the folding counter-supports, or to move it between two folding counter-supports in order to apply at least one fold to the cushioning material. The distance or clearance between two folding counter-supports may be smaller than the longitudinal extent or dimension by which the cushioning material is guided through the two folding counter-supports.

[0030] In a further exemplary embodiment of the arrangement according to the invention, the arrangement comprises at least one holding device for stationary holding of the transport container and / or the goods being shipped. This facilitates the filling process and allows it to be pre-programmed or set. Furthermore, programming is simplified because the holding device can be capable of keeping the transport container and / or the goods being shipped in the same position at all times. In particular, the holding device is designed to hold the transport container and / or the goods being shipped stationary when the transfer device is in the second position. It has been found that when filling the transport containers with the transfer device, the transport container can shift if it is not held stationary. This complicates the automated filling process using the arrangement according to the invention.

[0031] In an exemplary embodiment of the present invention, the arrangement comprises a dispensing device for supplying cushioning material or at least one individual cushioning unit as cushioning material into the dispensing area, which can be configured to form and / or supply any cushioning products or cushioning units. For example, the dispensing device comprises a cushioning material forming device, which can be configured according to one of the aspects or exemplary embodiments described above. For example, the cushioning material forming device is designed and configured to form a strand-shaped cushioning material with at least one crumple cavity from at least a single-layer web-shaped starting material, in particular a paper web.

[0032] In a further exemplary embodiment of the present invention, a dispensing element, in particular a dispensing opening, of the cushioning material forming device, from which a produced cushioning material, in particular a cushioning unit, can be removed, forms at least a portion of the supply area. For example, the transfer device can be associated with the supply device in such a way that the transfer device can remove the produced paper cushion or, in particular, the supplied paper cushion from the supply device via the dispensing element, in particular the dispensing opening, and in particular, can pull it off.

[0033] An advantage of the exemplary embodiment of the arrangement according to the invention is that the transfer device and the dispensing device are arranged in such a way that the transfer device is able to take the paper cushion directly from the dispensing device, in particular directly from the dispensing opening of the dispensing device. Especially for automated packaging material processing or production, it is advantageous if the gripping of the paper cushion by the transfer device is as simple and / or as repetitive as possible. This can be facilitated by ensuring that the dispensing or gripping position at which the transfer device grasps and pulls off the paper cushion is always the same or reproducible.Furthermore, it has been found that another advantage lies in the fact that the orientation of the generated paper cushion, while still held by the dispensing device, remains consistent with minimal deviation. This also facilitates the reliable handling of the paper cushion by the transfer device. Another advantage of the station is that the handling and placement of packaging material into a transport container is carried out with high positional and quantity accuracy.

[0034] In an exemplary embodiment of the arrangement according to the invention, the dispensing device is designed and configured to provide cushioning material or at least one cushioning unit of a predetermined size in the dispensing area. For example, the dispensing device can be configured and designed to provide the cushioning material or the at least one cushioning unit, tailored to an individual cavity, which can be determined or is predetermined, for example, by means of the dispensing device, in particular its sensors, within a specific transport container detected by at least one sensor, in the dispensing area.For example, a number of predetermined sizes for cushioning units can be predefined, and the dispensing device can be configured to select the appropriate cushioning material unit from these predefined sizes based on user input or specifications. The detection and subsequent dispensing of a desired cushioning material size can also be based on sensors on the dispensing device, ensuring that the individually determined cavity volume is cushioned and filled as precisely as possible.

[0035] In a further exemplary embodiment of the present invention, the dispensing device is designed to provide different cushioning materials and / or cushioning units. For example, the dispensing area can have several sections for the different cushioning materials and / or different cushioning units. The dispensing device can then be designed to approach or operate the corresponding section in the dispensing area depending on the size of the cushioning material or other characteristics of the cushioning material or the cushioning unit.

[0036] According to a further exemplary embodiment of the arrangement according to the invention, the arrangement comprises a conveying device, such as a conveyor belt, for transporting the cushioning material or the at least one cushioning unit to the staging area and / or a cushioning magazine for receiving a plurality of cushioning units. For example, the conveying device can be part of the staging device. The operation of the conveying device and the operation of the staging device can be coordinated. For example, the two components are coordinated such that the staging device becomes active when the conveying device emits a specific signal or has completed a specific conveying section.

[0037] In a further exemplary embodiment of the present invention, the arrangement comprises a transport device, such as a conveyor belt, for the particularly automated transport of the transport container, especially one containing at least one shipment item, preferably in a container filling area accessible from the transfer device. Conveyor belts and conveyors have proven advantageous for automating the filling process. The operation of the transport device can be coordinated with that of the other components, so that the conveyor belt is operated, for example, continuously, intermittently, or in response to control signals from the other upstream and / or downstream components.

[0038] According to a further exemplary embodiment of the present invention, the arrangement comprises at least one sensor for detecting at least one cavity within an individual transport container with at least one shipment inside, and / or at least one sensor for detecting an identifier of an individual transport container with at least one shipment inside, and / or electronics designed and configured to determine the size of the cavity, in particular based on sensor readings and / or information associated with the identifier. For example, the identifier can be acquired contactlessly, in particular by means of a barcode, RFID tag, or the like.The data can be stored in an external system, specifying predetermined transport container volumes, paper cushion requirements such as stiffness or number of cushions, as well as desired cushion sizes and shapes. Based on this database, the dispensing device can then provide a customized paper cushioning product, which is transferred into the transport container via the transfer device. Alternatively or additionally, artificial intelligence can be used, particularly when no data, such as the weight of the shipment, is available. In this case, the artificial intelligence can be used to generate or query relevant parameters or data. Furthermore, the artificial intelligence can be capable of, and used to, determine the appropriate parameters based on the aforementioned data.The database and / or, depending on sensor data, to generate further data and / or parameters. For example, artificial intelligence can determine an anticipated density and quantity of the desired cushioning product depending on the weight of the item being shipped.

[0039] In a further exemplary embodiment of the arrangement according to the invention, the arrangement comprises a control unit assigned to the transfer device for controlling the operation of the transfer device. The control unit for signal transmission can be connected to a drive of the transport device. In particular, the control unit is coupled to a drive of the transport device for signal transmission purposes, so that the operation of the transport device and the transfer device can be coordinated. According to an exemplary further development, the control unit is configured to coordinate the operation of the transfer device and that of the transport device.

[0040] According to a further aspect of the present invention, which can be combined with the preceding aspects and exemplary embodiments, a method for filling a cavity and a transport container containing at least one shipment item and at least one paper cushioning unit are provided. According to the method, cushioning material is provided in a cushioning dispensing area and the cushioning material is moved from the dispensing area into the cavity.

[0041] According to the inventive method, an arrangement according to one of the aspects or exemplary embodiments described above is used. The advantages and embodiments described with regard to the arrangement are therefore transferable to the inventive method.

[0042] Preferred embodiments are specified in the dependent claims.

[0043] Further properties, features and advantages of the invention will be clarified below by describing preferred embodiments of the invention with reference to the accompanying exemplary drawings, which show: Fig. 1 a schematic diagram of an exemplary embodiment of an arrangement according to the invention; Fig. 2 a schematic principle sketch of two exemplary operating positions of a gripper of an arrangement according to the invention; Fig. 3 a further schematic principle sketch of a gripper of an arrangement according to the invention with a cushioning unit; Fig. 4-6 schematic principle sketches of an exemplary embodiment of an arrangement according to the invention, which places a cushioning unit into a transport container; Fig. 7-10 further schematic principle sketch for an exemplary implementation of an arrangement according to the invention; Fig. 11 a detailed view of a gripper designed as a needle gripper of an exemplary embodiment of an arrangement according to the invention; and Fig. 12 of the needle grippers from Fig. 12 in intervention with a cushion unit.

[0044] In the following description of exemplary embodiments of the present invention, an arrangement according to the invention is generally designated by reference numeral 1. The arrangement 1, which can also be referred to as a paper cushion processing station, is designed, according to the exemplary embodiments, as a self-contained or automated station, in particular a robotic cell, which, starting from a material supply or a starting material to be processed into a cushioning unit 101, inserts the three-dimensional, cushioning and damping cushioning unit 101 into an empty transport container 201 or one already containing goods to be shipped and packaged.

[0045] The arrangement 1 according to the invention essentially comprises the following main components, which are shown in the schematic diagram in Fig. Figure 1 shows: A cushion material forming device 11, which is capable of producing a strand-shaped cushion material or a cushion unit 101, in particular with at least one lateral crumple cavity and a central deformation band; a supply device 5 for supplying cushion material or at least one isolated cushion unit 101; a transfer device 3 with a gripper 7 for grasping and / or handling cushion material or at least one isolated cushion unit 101; and a transport container 201, in which a shipment item 203 can be arranged, as well as a cavity 205, which can be used for filling with cushion material or the cushion unit 101.

[0046] Based on Fig. 1. It is evident that the transfer device 3 is movable between a first position (shown in Fig. 1) corresponding to a provision area 51 for cushioning material or a cushioning unit 101 and a second position for placing cushioning material or a cushioning unit 101 into the cavity 205 of the transport container 201.

[0047] In Fig. Figure 2 is a schematic diagram of an exemplary embodiment of a gripper 7, which is designed as a finger gripper, showing the transfer device 3 in two different operating positions, namely: In Fig. 2, on the left, is the gripper 7, which is equipped with at least two prongs 71, which can be designed as elongated, rod-shaped components and, for example, round in cross-section, in a passive position in which the prongs 71 are spaced apart. Fig. 2, on the right, shows the active position of the gripper 7, in which the tines 71 are brought close together, for example to grip a cushion unit 101 ( Fig. 3) to grasp and wedge between the prongs 71.

[0048] In Fig. Figure 3 shows the active or gripping state of the gripper 7, whose tines 71 clamp the cushioning unit 101 in a free space 73 existing between the two tines. In the embodiment according to Fig. 3 The gripper 7, with its two tines 71, grasps or grips the strand-shaped cushioning unit 101 centrally (reference numeral 105) between the two longitudinal ends 103 of the cushioning unit that point in the longitudinal direction of the strand. By means of the transfer device 3, the cushioning unit 101, grasped by the tines 71, can be inserted into the cavity 205 of the transport container 201 ( Fig. 4). In Fig. Figure 4 is a transport container 201, which is loaded with a shipment 203, shown first in a side view and second in a top view. The paper cushioning unit 101 is inserted into the cavity 205 by means of the transfer device 3. To form a well-cushioned, space-saving cushioning spiral 107, the tines 71 can be rotated about a spindle axis indicated by the reference numeral S, which is indicated by the arrow with the reference numeral W, in order to advance the paper cushioning strand 101 according to Fig. 3 to the in Fig. 4. to wind up the cushioning spiral 107 shown below. In this way, the cushioning strand 101 then adapts to the available cavity 205 in the form of the cushioning spiral 107 and is therefore particularly effective in damping and cushioning the goods being shipped 203.

[0049] In Fig. 5 is another schematic principle sketch analogous to Fig. Figure 4 shows that two cushioning screws 107 are inserted into the cavity 205 of the transport container 201 by means of the transfer device 3. The same applies to the embodiment according to Fig. 5 The cushioning screws 107 are only produced within the cavity 205, that is, only directly at the desired location of damping or cushioning, by the transfer device 3 winding up a cushioning screw 107 by means of the gripper 7.

[0050] In Fig. Figure 6 schematically illustrates the progress in the formation of the cushion snail 107 starting from the strand-like cushion unit 101 in three consecutive figures. Fig. 6, above, the cushion strand 101, held by means of the transfer device 3 and in particular its prongs 71, is inserted into a free space 205 on the upper side of the goods being shipped 203 in the transport container 201. Fig. 6, In the middle, the cushion strand 101 was already partially wound up, so that a cushion intermediate product 109 was formed, which had already formed a winding in sections. In Fig. 6, below the cushioning spiral 107 is fully formed and optimally cushions the shipping goods 203 in the cavity 205 of the transport container 201.

[0051] The arrows in Fig. Figure 5 indicates the movement capability of the transfer device 3. The arrow with the reference numeral W represents the winding movement by which the cushion screw 107 is formed. The reference numeral R defines a rotational or pivoting movement, according to which the transfer device 3 or the gripper 7 can assume an orientation deviating from the vertical. The arrow with the reference numeral T denotes a translational axis, along which the transfer device 3 can move the gripper 7 translationally, in particular for inserting and removing the gripper into and out of the cavity 205 of the transport container 201.

[0052] Referring to the Fig. Figures 7-10 show a further exemplary embodiment of an arrangement 1 according to the invention, illustrating how a paper cushion strand 101 can be folded to form the strand-shaped paper cushion unit 101 into a desired paper cushion product shape. For this purpose, the arrangement 1 includes, by way of example, three folding counter-supports 41, 42, and 43, which are elongated and / or pin-shaped and serve as a stop for the paper cushion strand 101, so that the paper cushion product 101 can be folded by feeding, passing through, or advancing the paper cushion 101 by means of the transfer device 3. According to the exemplary embodiment, the folding counter-supports 41, 42, and 43 are each arranged at a distance from one another, such that, as shown schematically in Figure 7-10, the folding counter-supports 41, 42, and 43 are arranged at a distance from one another, such that, as shown schematically in Figure 7-10, the paper cushion product 101 can be folded. Fig. Figure 8 shows the transfer device 3, by means of which the clamping or holding prongs 71 of the cushioning product 101 can be guided along the direction of movement B between the folding counter-bearings 41, 42, 43, which serve as a rigid stop for the paper cushion strand 101 and cause the formation of a fold 104, so that the strand sections 111 extending from the center 105 of the paper cushion strand 101 are facing each other and can at least partially rest on each other.

[0053] In Fig. 9 is a paper cushion intermediate product 109 and is located between the folding counter-supports 41, 42. The transfer device 3 can further change the shape of the intermediate product 109 or grasp the intermediate product 109 by means of the prongs 71. For example, the transfer device 3 can retract the approaching prongs 71 into a free space formed between the strand sections 111 in order to lift the cushion intermediate product 109 not by clamping, but in a manner similar to a stacker or lifting device. Fig. 10 shows that, for example, according to order 1 from Fig. 9 formed cushion intermediate product 109 is gripped by means of the prongs 71, whereby the strand sections 111 are pressed against each other.

[0054] In the Fig. 11 and Fig. Figure 12 shows a schematic principle sketch of a gripper designed as a needle gripper 9, which is provided with needles 15 that can penetrate the paper material to securely hold and fix the cushioning material or cushioning unit 109 or cushioning products 101, 109, 115.

[0055] The needle gripper 9 comprises several needles 15 extending or oriented transversely to each other and movable in this direction, which can shear past each other to hook onto the paper pad 101 to be gripped. This is shown schematically in Fig. 12 shown.

[0056] The features disclosed in the foregoing description, figures and claims can be important for the realization of the invention in its various embodiments, both individually and in any combination. Reference symbol list 1. Arrangement 3 Transfer device 4 folding units 5 Provisioning device 7 grippers 9 needle grippers 11 Upholstery material forming device 15 needles 41, 42, 43 Folding counter bearing 51 Deployment area 71 prongs 101 Upholstery unit 103 Longitudinal end 104 folds 105 Middle 107 Cushion snail 109,115 Cushion intermediate product 111 strand section 113 Free space 201 transport containers 203 Shipping goods 205 cavity X Longitudinal direction Y transverse direction Z Vertical direction S spindle axis R direction of rotation T Translation direction B Direction of movement W winding direction QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] EP 1 556 278 B1

[0002] US 11 053 041 B2

[0003] EP 1 015 240 B1

[0003] WO 2019 / 174800 A1

[0004] WO 1998 021 101 A1

[0005]

Claims

[1] Arrangement (1) for filling cavities (205) in transport containers (201) with cushioning units (101) made of paper, comprising a transfer device (3) which is movable between a first position corresponding to a provision area (51) for cushioning material and a second position for placing cushioning material or a cushioning unit (101) made of the cushioning material in a cavity (205) of a transport container (201), characterized by that the transfer device (3) has a needle gripper. [2] Arrangement (1) according to claim 1, characterized by that the needle gripper has at least two, preferably a plurality of, needles and has a gripping state in which the needles are extended, and a rest state in which the needles are retracted. [3] Arrangement (1) according to claim 2, characterized bythat a direction of movement of a needle during retraction and extension, in particular with respect to a housing of the needle gripper, is aligned transversely to a direction of movement of another needle during retraction and extension, wherein in particular the needles, preferably their directions of movement, are arranged relative to one another in such a way that the needles shear past one another. [4] Arrangement (1) according to one of claims 2 to 3, characterized by that the needles, when entering the rest state, retract in particular into a housing of the needle gripper in such a way that a cushioning material gripped by the needles is stripped off in order to release the cushioning material. [5] Arrangement (1) according to one of the preceding claims, characterized bya cushioning material forming device (11) which is designed and configured to form a strand-shaped cushioning material with two crumple cavities extending in the longitudinal direction of the strand and a central deformation band connecting the crumple cavities, wherein in particular the shape of a gripping side of the needle gripper facing the cushioning material is matched to the cushioning material formed, wherein in particular the needle gripper has a central gripping section for engaging in the deformation band and two lateral contact sections for the crumple cavities, which are offset back with respect to the gripping section. [6] Arrangement (1), in particular according to one of the preceding claims, for filling cavities (205) in transport containers (201) with cushioning units (101) made of paper, comprising a transfer device (3) which is movable between a first position corresponding to a provision area (51) for cushioning material and a second position for placing cushioning material or a cushioning unit (101) made of the cushioning material in a cavity (205) of a transport container (201), characterized by in that the transfer device (3) comprises a gripper (7) with at least two prongs (71) for gripping the cushioning material or the cushioning unit (101), wherein the gripper (7) has a passive state with prongs (71) spaced apart from one another and an active state with prongs (71) brought closer together. [7] Arrangement (1) according to one of the preceding claims, characterized bythat the transfer device (3), in particular with the gripper (7), is movable in a guided translational manner in at least two, preferably three, directions (X, Y, Z), wherein in particular the arrangement (1) has a guide for the guided movement of the gripper (7) with the transfer device (3) in at least one direction, preferably two or three directions (X, Y, Z). [8] Arrangement (1) according to claim 6 or 7, characterized byin that the prongs (71) are at least partially needle-shaped in order to penetrate into the cushioning material in the active state for gripping the cushioning material, wherein in particular the prongs (71) comprise at least two prongs (71) which are movable relative to one another along their needle extension direction from the passive state to the active state, wherein in particular the gripper (7) is designed and configured to cooperate with a plastically deformed, in particular punch-perforated and / or roller-embossed, deformation region of the cushioning material. [9] Arrangement (1) according to one of claims 6 to 8, characterized by that the at least two prongs (71) are designed with clamping jaws for non-positively gripping, in particular clamping, the cushioning material between opposite clamping surfaces of the clamping jaws in the active state. [10] Arrangement (1) according to one of the preceding claims, characterized byin that the gripper (7) or the needle gripper for winding up the cushioning material or the cushioning unit (101) into a cushioning screw is rotatable about a spindle axis (S), which preferably forms an axis of symmetry with respect to the tines (71), wherein in particular the arrangement further comprises a guide device for supporting the formation of the cushioning screw, wherein in particular the guide device is assigned to the gripper (7) or the needle gripper in such a way that the guide device guides the cushioning screw being formed transversely, in particular perpendicularly, to the spindle axis (S). [11] Arrangement (1) according to claim 10, characterized by that the transfer device (3) is designed and arranged to insert the gripper (7) into the cavity (205) of the transport container (201) and to cause the cushioning material to be wound up into a cushioning screw within the cavity (205). [12] Arrangement (1) according to one of the preceding claims, characterized bya separating device for separating a cushioning unit (101) from the cushioning material, in particular held in the active state by the gripper (7). [13] Arrangement (1) according to one of the preceding claims, characterized by that the transfer device (3) is designed to grip the cushioning material or the cushioning unit (101) at a longitudinal end (103) and / or to grip the cushioning unit (101) centrally (105) relative to its longitudinal extent. [14] Arrangement (1) according to one of the preceding claims, characterized by that the transfer device (3), in particular the gripper (7), comprises at least one sensor, such as a position, force and / or torque sensor, wherein in particular the transfer device (3) is designed to initiate a holding and / or safety state of the gripper (7) or the needle gripper upon the occurrence of a predetermined measurement signal from the sensor, such as a maximum torque threshold value. [15] Arrangement (1) according to one of the preceding claims, characterized by at least one folding unit (4) with at least one folding counter-bearing (41, 42, 43), in particular two or three folding counter-bearings (41, 42, 43), wherein the transfer device (3) is designed and configured to move the cushioning material by means of the gripper (7) or the needle gripper relative to the at least one folding counter-bearing (41, 42, 43), in particular against at least one folding counter-bearing (41, 42, 43) or between two folding counter-bearings (41, 42, 43) in order to apply at least one fold (104) to the cushioning material. [16] Arrangement (1) according to one of the preceding claims, characterized byat least one holding device for holding the transport container (201) and / or the shipping goods in a stationary manner, wherein in particular the holding device is designed to hold the transport container and / or the shipping goods in a stationary manner when the transfer device (3) is in the second position. [17] Arrangement (1) according to one of the preceding claims, characterized bya provision device (5) for providing cushioning material or at least one individual cushioning unit (101) made of cushioning material in the provision area (51), in particular comprising a cushioning material forming device (11) which is preferably designed and configured to form a strand-shaped cushioning material with at least one crumple cavity from an at least single-layer web-shaped starting material, preferably a paper web, wherein in particular a discharge opening of the cushioning material forming device (11), from which a produced cushioning material, in particular a cushioning unit (101), can be removed, forms the provision area (51) at least in sections. [18] Arrangement (1) according to claim 17, characterized byin that the provision device (5) is designed and configured to provide cushioning material or at least one cushioning unit (101) of a predetermined size in the provision area (51), wherein in particular the provision device (5) is designed and configured to provide the cushioning material or the at least one cushioning unit (101) in a manner adapted to an individual cavity (205) of a specific transport container (201) detected by means of at least one sensor in the provision area (51). [19] Arrangement (1) according to one of claims 17 or 18, characterized by that the provision device (5) is designed to provide different upholstery materials and / or different upholstery units (101), wherein in particular the provision area (51) has a plurality of sections for the different upholstery materials and / or different upholstery units (101). [20] Arrangement (1) according to one of the preceding claims, characterized by a conveying device, such as a conveyor belt, for transporting the cushioning material or the at least one cushioning unit (101) to the provision area (51) and / or a cushioning magazine for receiving a plurality of cushioning units (101), wherein in particular the conveying device is part of the provision device (5). [21] Arrangement (1) according to one of the preceding claims, characterized by at least one transport device, such as a conveyor belt, for the particularly automated transport of the transport container (201), in particular with at least one item of shipping material inside, preferably into a container filling area accessible by the transfer device. [22] Arrangement (1) according to one of the preceding claims, characterized byat least one sensor system for detecting at least one hollow space (205) within an individual transport container (201) with at least one item of shipping material inside and / or at least one sensor system for detecting an identifier of an individual transport container (201) with at least one item of shipping material inside and / or electronics which are designed and configured to determine the size of the hollow space, in particular on the basis of measured values from the sensor system and / or an item of information associated with the identifier. [23] Arrangement (1) according to one of the preceding claims, characterized by an alignment station by means of which the transport container (201) can be arranged in a predefined position, wherein in particular the alignment station has two alignment edges against which the transport container (201) can be placed in order to assume the predefined position, and / or is part of the holding device. [24] Arrangement (1) according to one of the preceding claims, characterized bya controller assigned to the transfer device for controlling the operation of the transfer device, wherein the controller is designed for signal transmission with a drive of the transport device, wherein in particular the controller is designed to coordinate the operation of the transfer device and the transport device with one another. [25] Method for filling a cavity (205) in a transport container occupied with at least one shipping item with at least one cushioning unit (101) made of paper, wherein cushioning material is provided in a provision area (51) and the cushioning material is moved from the provision area (51) into the cavity (205), characterized by that at least one arrangement (1) according to one of the preceding claims is used.

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