Packaging-material-processing station and method for operating a packaging-material-processing station

Abstract

The present invention relates to a packaging-material-processing station (1) comprising: a paper-cushion-production device (15) having an output (29) from which a produced paper cushion (9) can be removed; and a robot (17) which is associated with the paper-cushion-production device (15) in such a way that the robot (17) can remove the produced paper cushion (9) from the paper-cushion-production device (15) via the output (29).

Description

[0001] Packaging material processing station and method for operating a packaging material processing station

[0002] The present invention relates to a packaging material processing station and a corresponding operating method, in particular for filling a cavity in a transport container, which is occupied with at least one shipping item, with at least one paper cushion.

[0003] The present invention is fundamentally about processing packaging material, in particular in an automated manner, producing paper cushions, and inserting any paper cushions produced into cavities of transport containers which are, for example, occupied with a shipping item, as well as lining transport containers for receiving and bedding shipping items with paper cushions.

[0004] A similar packaging station is known, for example, from EP 3464 080 B1. The packaging station is used for the automatic packaging of upholstery products in a carton and comprises a robot cell with a gripping device and a supply of packing material. The gripping device comprises two jaws movable along a longitudinal axis for clamping the upholstery product to be gripped.

[0005] Another similar packaging station is known from EP 1 498 258 B1. The packaging station is designed to produce cushioning products and place them into a container by means of a gripper, which is configured to grip the voluminous cushioning product from the outside transversely to its longitudinal extent, compress it slightly, and finally place it into the transport container.

[0006] The known packaging stations have shown deficiencies in particular with regard to the speed and throughput of the station as well as with regard to interruptions, which are mainly necessary to correct incorrect manipulation of the gripping devices.

[0007] An object of the present invention is to overcome the disadvantages of the prior art, in particular to provide a packaging material processing station with increased throughput and / or reduced downtimes.

[0008] The problem is solved by the subject matter of the independent claims.

[0009] According to this, a packaging material processing station, also called a paper cushioning processing station, is provided, which comprises a paper cushioning production device with a discharge, such as a discharge opening from which a produced paper cushion can be removed, and a robot which is assigned to the paper cushioning production device in such a way that the robot can remove, in particular pull, the produced paper cushion from the paper cushioning production device via or from the discharge. A robot can be understood as an autonomous machine or a handling device which is intended to perform tasks or functions which imitate or replace human actions. The robot can have the ability to interact with its environment, process information and perform actions without direct human control or direct human intervention.The robot can be programmable, specifically programmed to perform specific tasks or functions independently or under the control of a human operator. Different 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 have sensors to collect data about its environment, such as cameras, microphones, or other specialized sensors that can serve as the basis for decision-making. 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.In other words, the paper cushioning production device is a device for producing 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 production of a three-dimensional packaging product is understood, in particular, to mean the conversion of a web-shaped starting material into a state with a greater extension in the direction of the starting material's thickness than the starting material. For ecological reasons, recycled paper is increasingly being used as the paper material. However, due to its inhomogeneity, this paper is difficult to convert, especially if the three-dimensional packaging product must always be uniform and manufactured as simply and economically as possible.The starting material web can be made from paper, such as recycled paper, in particular waste paper and / or 100% recyclable paper, which can be produced without chemical ingredients. Recycled paper is, in particular, paper materials with a low proportion (less than 50%) of paper material containing virgin fibers. 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 can have 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. A standard such as DIN EN ISO 1924-2 or DIN EN ISO 1924-3 can be used to determine the tensile strength or the tensile strength index.Additionally, or alternatively, a recycled paper or waste paper property can be characterized by its so-called burst resistance. A material in this sense is recycled paper with a burst index of 3.0 kPa*m or less. A 2 / g, preferably with a burst index of 0.8 kPa*m A 2 / g to 2.5 kPa*m A2 / g. The DIN EN ISO 2758 standard is used to determine the bursting index. Furthermore, the packaging material has a mass per unit area 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 fanfold stack. For example, the paper cushion is a strand-like cushioning material with two crumple cavities extending in the longitudinal direction of the strand and a central deformation band connecting the crumple cavities. This deformation band can be deformed and, for example, embossed, punched, perforated, or similar.

[0010] One advantage of the station according to the invention is that the robot and the paper cushioning device are assigned to one another in such a way that the robot is able to remove the paper cushion directly from the discharge, in particular pull it off directly from the discharge opening of the paper cushioning device. Particularly for automated packaging material processing or production, it is advantageous if the gripping of the paper cushion is as simple and / or as repetitive as possible for the robot. This can be promoted by ensuring that the discharge or gripping position, at which the robot grips and pulls off the paper cushion, is always the same or reproducible if possible. Furthermore, it has been found that a further advantage lies in the fact that the orientation of the produced paper cushion, when it is still held by the paper cushioning device, is always the same with the smallest deviation.This also facilitates the robot's reliable gripping of the paper cushion. Another advantage of the station is that the handling and placement of packaging material into a transport container is carried out with high positioning and / or quantity accuracy.

[0011] In an exemplary embodiment of the present invention, the paper cushioning device has a dispensing and / or cutting device for dispensing and / or cutting a paper cushion to length, arranged upstream of the dispensing device. Furthermore, the paper cushioning device is designed such that a produced paper cushion does not leave the paper cushioning device exclusively under the influence of weight. In other words, the dispensing device is designed to hold a produced paper cushion, which may already have been cut to length from the trailing paper cushioning strand. In this way, it is ensured that the produced paper cushion, which is ready for further processing, is located at a desired, predefined dispensing or gripping position and / or in the desired, predefined orientation, so that the robot can grasp and pull off or take / grasp the paper cushion reliably and reproducibly.

[0012] In an exemplary development of the packaging material processing station according to the invention, the dispensing and / or cutting-to-length device and the dispensing device are arranged in relation to one another and / or a length of the paper cushion to be produced is selected, in particular set, in such a way that a produced paper cushion protrudes from the dispensing opening by at least 2 cm, in particular at least 3 cm, 4 cm or at least 5 cm. This already reliably ensures that a sufficient length of paper cushion is available which can be reliably gripped by the robot. Furthermore, in particular depending on the length of the paper cushion to be produced, it is further ensured that this does not fall out of the paper cushion producing device on its own, i.e. solely under the influence of weight.

[0013] In another embodiment, the paper cushion length is variable by the paper cushion generation device. The length is based on the corresponding dimensions of the transport container. The length of the paper cushion can be set slightly shorter if the paper cushion is intended to fall easily into the transport container. The length of the paper cushion can be set slightly longer if the paper cushion is intended to be firmly inserted into the transport container. Furthermore, such lengths of a paper cushion can be designed incrementally or continuously.

[0014] It can further be provided that the packaging processing station transmits the required length of paper cushioning in the form of an electrical and / or data signal to the paper cushioning generation device. For this purpose, the packaging processing station has sensors that detect the characteristic dimensions of the transport container, such as the length and / or width. Detection occurs either by measuring using a suitable sensor or by sensor detection of predetermined transport container sizes. Detection occurs in a simplified manner using light barriers or reflective light sensors. The latter are provided and configured to detect the respective type of transport container, such as small transport container, medium-sized transport container, or large transport container, and to transmit the information to the control system.The controller then transmits the length of the paper cushion corresponding to the transport container to the paper cushion generating device.

[0015] Alternatively, the transport container can have an optically readable identifier such as a machine-readable label, a code, a barcode, a QR code, or the like. The control system of the packaging processing station further includes an executable program configured and intended to determine the required length of the paper cushion and to have it generated by the paper cushion generation device.

[0016] According to a further aspect of the present invention, which can be combined with the exemplary embodiments of the preceding aspects, a packaging material processing station is provided.

[0017] The packaging material processing station comprises a paper cushion producing device with a discharge, in particular a discharge opening, from which a produced paper cushion can be removed, and a robot for gripping the produced paper cushion.

[0018] In other words, the paper cushioning production device is a device for producing 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 production of a three-dimensional packaging product is understood, in particular, to mean the conversion of a web-shaped starting material into a state with a greater extension in the direction of the starting material's thickness than the starting material. For ecological reasons, recycled paper is increasingly being used as the paper material. However, due to its inhomogeneity, this paper is difficult to convert, especially if the three-dimensional packaging product must always be uniform and manufactured as simply and economically as possible.The starting material web can be made from paper, such as recycled paper, in particular waste paper and / or 100% recyclable paper, which can be produced without chemical ingredients. Recycled paper is, in particular, paper materials with a low proportion (less than 50%) of paper material containing virgin fibers. 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 can have 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. A standard such as DIN EN ISO 1924-2 or DIN EN ISO 1924-3 can be used to determine the tensile strength or the tensile strength index.Additionally, or alternatively, a recycled paper or waste paper property can be characterized by its so-called burst resistance. A material in this sense is recycled paper with a burst index of 3.0 kPa*m or less. A 2 / g, preferably with a burst index of 0.8 kPa*m A 2 / g to 2.5 kPa*m A2 / g. The DIN EN ISO 2758 standard is used to determine the bursting index. Furthermore, the packaging material has a mass per unit area 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 fanfold stack. For example, the paper cushion is a strand-like cushioning material with two crumple cavities extending in the longitudinal direction of the strand and a central deformation band connecting the crumple cavities. This deformation band can be deformed and, for example, embossed, punched, perforated, or similar.

[0019] According to a further aspect of the present invention, the robot has a needle gripper. The needle gripper has proven particularly advantageous for paper cushions, which are generally made of a thin-layered material and are designed to be flexible. Furthermore, the paper cushions can be flexible due to their low inherent rigidity, which makes gripping the paper cushions difficult. The needle gripper can be designed to pierce the paper cushions, in particular to hook onto them, so that secure gripping and, above all, subsequent movement and / or handling of the paper cushions is possible. Because the paper material of the paper cushions is generally very thin-layered, the needles of the needle gripper can be very short. In this respect, the paper cushion can be securely gripped and further handled using 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 extent, allowing the paper cushion to only give way slightly when the needles are driven in. This in turn increases the reliability of gripping the paper cushion. Since the paper inherently gives way at least somewhat when the needles are driven in, they are driven into already pre-consolidated sections of the cushioning strand, such as a central area where several layers of paper are pressed together relatively tightly. This allows the needles to be driven through several layers of paper, which only give way slightly due to the consolidation. This ensures a very secure grip of the cushion by the needle gripper.

[0020] In an exemplary development of the packaging material processing station according to the invention, the needle gripper has at least two, preferably a plurality of, needles and a gripping state in which the needles are extended, as well as a rest state in which the needles are retracted. By retracting the needles in the rest state, the needle gripper can perform a stripping function that supports the release or discharge of the paper cushion gripped by the needle gripper. Furthermore, the risk of injury to any operators is reduced if the needles are not extended, in particular do not protrude, in the rest state.

[0021] In a further exemplary embodiment of the present invention, a direction of movement of a needle during retraction and extension is oriented, particularly with respect to a housing of the needle gripper, transverse to a direction of movement of another needle during retraction and extension. In an exemplary development, the needles, preferably their directions of movement, are arranged and / or aligned in such a way that the needles shear past one another. If a plurality of needles are present, at least two of them shear past one another directly. For example, the needles shearing past one another can cross one another. As a result, the crossing needles hook into the paper material of the paper cushion, whereby the latter can be gripped and held even more reliably. Alternatively, the needles can also move away from one another, in particular in order to cover the largest possible area.

[0022] According to a further exemplary embodiment of the packaging material processing station according to the invention, when the needles enter the rest state, they retract, in particular, into a housing or a receptacle of the needle gripper that carries and / or stores the needles, such that a paper pad gripped by the needles is stripped off to release the paper pad. For example, the housing or receptacle can have a stripping surface, in particular a flat one, facing the paper pad, relative to which the needles are set back in the rest state and / or protrude in the gripping state.

[0023] According to a further aspect of the present invention, which can be combined with the exemplary embodiments of the preceding aspects, a packaging material processing station is provided.

[0024] The packaging material processing station comprises a paper cushion producing device having a discharge, such as a discharge opening, from which a produced paper cushion can be removed, and a robot for gripping the produced paper cushion.

[0025] In other words, the paper cushioning production device is a device for producing 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 production of a three-dimensional packaging product is understood, in particular, to mean the conversion of a web-shaped starting material into a state with a greater extension in the direction of the starting material's thickness than the starting material. For ecological reasons, recycled paper is increasingly being used as the paper material. However, due to its inhomogeneity, this paper is difficult to convert, especially if the three-dimensional packaging product must always be uniform and manufactured as simply and economically as possible.The starting material web can be made from paper, such as recycled paper, in particular waste paper and / or 100% recyclable paper, which can be produced without chemical ingredients. Recycled paper is, in particular, paper materials with a low proportion (less than 50%) of paper material containing virgin fibers. 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 can have 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. A standard such as DIN EN ISO 1924-2 or DIN EN ISO 1924-3 can be used to determine the tensile strength or the tensile strength index.Additionally, or alternatively, a recycled paper or waste paper property can be characterized by its so-called burst resistance. A material in this sense is recycled paper with a burst index of 3.0 kPa*m or less. A 2 / g, preferably with a burst index of 0.8 kPa*m A 2 / g to 2.5 kPa*m A2 / g. The DIN EN ISO 2758 standard is used to determine the bursting index. Furthermore, the packaging material has a mass per unit area 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 fanfold stack. For example, the paper cushion is a strand-like cushioning material with two crumple cavities extending in the longitudinal direction of the strand and a central deformation band connecting the crumple cavities. This deformation band can be deformed and, for example, embossed, punched, perforated, or similar.

[0026] According to a further aspect of the present invention, the packaging material processing station comprises at least two mutually independent paper cushioning supply lines, each with a paper cushioning production device and a robot for grasping a produced paper cushion from or out of the respective paper cushioning production device. For example, the paper cushioning supply lines, in particular their robots, can be configured and / or coordinated with one another such that they can insert paper cushions into the same transport container. A paper cushioning supply line can encompass all process steps, starting from the provided starting material / paper material web, up to the transfer or forwarding of a finished paper cushion by means of the robot of the paper cushioning supply line.By running two or more supply lines in parallel, throughput can be doubled or even multiplied. Furthermore, redundancy is provided, so that even if one of the lines fails, the station can continue operating.

[0027] In an exemplary embodiment of the packaging material processing station according to the invention, the at least two paper cushioning supply lines are coordinated with one another such that a paper cushion of one paper cushioning supply line is produced at a different time than a paper cushion produced by the other paper cushioning supply line. For example, the paper cushioning supply lines can operate according to a clock cycle. Alternatively or additionally, the at least two paper cushioning supply lines are coordinated with one another such that a produced paper cushion is gripped and / or released by the robot of one paper cushioning supply line at a different time, in particular with a different time delay, than a produced paper cushion by the other robot of the other paper cushioning supply line.For example, it is possible for both cushioning supply lines to access the same paper cushioning generation device. The time offset in the release of the paper cushions can result in particularly safe operation of the station, particularly because collisions between the robots can be avoided. According to a further aspect of the present invention, which can be combined with the exemplary embodiments of the preceding aspects, a packaging material processing station is provided.

[0028] The packaging material processing station comprises a paper cushion producing device having a discharge, such as a discharge opening, from which a produced paper cushion can be removed, and a robot for gripping the produced paper cushion.

[0029] In other words, the paper cushioning production device is a device for producing 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 production of a three-dimensional packaging product is understood, in particular, to mean the conversion of a web-shaped starting material into a state with a greater extension in the direction of the starting material's thickness than the starting material. For ecological reasons, recycled paper is increasingly being used as the paper material. However, due to its inhomogeneity, this paper is difficult to convert, especially if the three-dimensional packaging product must always be uniform and manufactured as simply and economically as possible.The starting material web can be made from paper, such as recycled paper, in particular waste paper and / or 100% recyclable paper, which can be produced without chemical ingredients. Recycled paper is, in particular, paper materials with a low proportion (less than 50%) of paper material containing virgin fibers. 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 can have 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. A standard such as DIN EN ISO 1924-2 or DIN EN ISO 1924-3 can be used to determine the tensile strength or the tensile strength index.Additionally, or alternatively, a recycled paper or waste paper property can be characterized by its so-called burst resistance. A material in this sense is recycled paper with a burst index of 3.0 kPa*m or less. A 2 / g, preferably with a burst index of 0.8 kPa*m A 2 / g to 2.5 kPa*m A2 / g. The DIN EN ISO 2758 standard is used to determine the bursting index. Furthermore, the packaging material has a mass per unit area 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 fanfold stack. For example, the paper cushion is a strand-like cushioning material with two crumple cavities extending in the longitudinal direction of the strand and a central deformation band connecting the crumple cavities. This deformation band can be deformed and, for example, embossed, punched, perforated, or similar.

[0030] According to a further aspect of the present invention, the packaging material processing station comprises a paper cushioning device with a discharge, such as a discharge opening, from which a produced paper cushion can be removed, a robot, and a depository arranged downstream of the paper cushioning device in the conveying direction, defining a predefined deposit position for a produced paper cushion, from which the robot can grasp the paper cushion. The depository functions as a kind of functional link between the paper cushioning device and the robot and / or as a standardized deposit location or receiving location for the robot.

[0031] In an exemplary embodiment of the packaging material processing station according to the invention, the storage area is inclined relative to the horizontal. The angle of inclination can be a few degrees. For example, the storage area is inclined starting from the discharge opening. Alternatively or additionally, the storage area can have a transfer interface facing the discharge, which is arranged at the vertical height of the discharge opening for receiving a paper cushion, and a storage surface adjoining the transfer interface, the vertical height of which decreases with increasing distance from the transfer interface. For example, the storage area is designed as a type of angled groove with a U- or V-shaped cross-section. By inclining the storage area or its storage surface relative to the horizontal, gravity can be utilized to automatically, i.e.under the influence of gravity, to slip or slide into the predefined storage position.

[0032] According to a further exemplary embodiment of the present invention, the tray has a concave and / or V- or U-shaped tray surface for placing a produced paper cushion. In other words, the tray can form or have a U- or V-shaped tray channel, the lateral V- or U-shaped legs of which enable the received paper cushion to be secured laterally.

[0033] According to an exemplary embodiment of a U-shaped support surface, it is formed by a one-piece U-profile whose lateral U-legs enable the held paper cushion to be laterally secured and guided. In a further embodiment of the U-profile, the middle leg is provided with openings in sections, which are arranged opposite the gripping device or opposite the respective needle gripper and its needles. This allows the needles to move into the respective opening when gripping the paper cushion, provided they pierce the paper cushion to do so. Contact with the U-shaped support surface and resulting damage to the needles is thus ruled out.Furthermore, the width of the openings of the middle U-profile leg, measured in width, is smaller than the length of the middle leg itself, so that at least a section of the middle leg remains as a storage and support for the paper cushion.

[0034] According to another advantageous embodiment of the U-shaped support surface, it is formed by two angle profiles arranged at a distance from one another, wherein the aforementioned opening extends at least along a section of both angle profiles and is also always arranged opposite the needles of a needle gripper or gripping device, provided that this grips and / or pierces and / or encompasses the paper cushion. According to the application, both angle profiles form a single unit and thus form the support surface. Even if the opening thus created extends as a slot between the angle profiles, both angle profiles as a whole nevertheless form the U-shaped support surface.

[0035] The packaging material processing station can further comprise a sensor arrangement connected to the output area of ​​the paper cushioning device and / or to the discharge opening and / or to the storage area. This sensor arrangement consists of at least one cushioning sensor for detecting whether the paper cushioning device has actually provided a paper cushion to the transport device for further transport. The at least one sensor of the sensor arrangement is designed to detect the produced paper cushion at a distal distance. Capacitive proximity sensors can be provided for shorter distances. However, reflective light sensors are advantageously provided, which offer the possibility of being arranged at a distance from the provided paper cushion.

[0036] In another exemplary embodiment of the packaging material processing station according to the invention, the robot is a multi-axis and / or articulated robot. For example, the robot's axes are designed as serial kinematics.

[0037] According to an exemplary development of the packaging material processing station according to the invention, the robot has a robot head with a gripping device arranged thereon, which has at least two grippers arranged at a distance from one another, such as a finger or needle gripper. Needle grippers grip the paper cushion from the side in a form-fitting manner using the driven-in needles. Finger grippers grip the paper cushion between fingers that can be moved relative to one another by clamping. This makes gripping the paper cushion safer and more reliable. According to an exemplary development, the robot further has a controller that is configured to control the grippers with the same control signal for simultaneous handling of a paper cushion or with a different control signal for independent handling of a paper cushion or different paper cushions.In this way, the packaging material processing station is designed to be very flexible and can be configured, in particular, depending on the paper cushions to be handled in order to ensure the best possible and most reliable production and handling of paper cushions.

[0038] In a further exemplary embodiment of the packaging material processing station according to the invention, it further comprises a housing in which the robot and, if applicable, a transport container to be filled with a produced paper cushion are accommodated, and on which the paper cushion generating device is arranged. For example, the paper cushion generating device can be arranged inside the housing or outside it. For example, the paper cushion generating device can be movably mounted with respect to the housing. In this way, a compact and / or self-contained station can be created which functions to cushion a transport container with a paper cushion produced by the robot cell. The housing can encapsulate the components, in particular for accident prevention.Furthermore, the station can be designed such that the robot and / or the paper cushioning device is capable of being moved / pivoted out of the housing area, so that the respective component is mechanically and electrically decoupled from the system and can be removed or replaced for maintenance and / or repair reasons.

[0039] According to a further exemplary development, the packaging material processing station further comprises a transport device, such as a conveyor belt, for example an endless conveyor belt, or a roller conveyor belt or the like, for the particularly automated transport of the transport container, in particular with at least one shipping item inside, preferably into a container filling area accessible by the robot. The conveyor belt can be operated continuously and / or have a rest state, particularly in the container filling area. Alternatively or additionally, the robot can be coordinated with a transport movement of the conveyor belt and transfer the paper cushion into the transport container, even if the container moves continuously with the conveyor belt.According to a further exemplary embodiment of the present invention, the packaging material processing station further comprises a controller and a communication technology linking the paper cushioning device, the robot and optionally the conveyor belt, for controlling operation of the packaging material processing station. Furthermore, the packaging material processing station according to the invention can also be equipped with sensors according to exemplary embodiments. The sensors can be linked to the controller; in particular, the controller can issue control commands depending on the sensors. For example, several controllers can be provided whose data is technically linked to one another, for example via a CAN bus. For example, the robot controller has the highest computing power and emits a signal when theThe robots have completed a work process, for example, by transferring a predetermined number of paper cushions to the transport container. Once the robots have moved far enough out of the transport container, the conveyor belt continues to move, depending on the sensors. The control system can monitor the inflow and outflow of transport containers. Furthermore, the transport of the transport containers can be interrupted when a new transport container reaches a predetermined position.

[0040] In a further exemplary embodiment of the present invention, the packaging material processing station further comprises an alignment unit downstream of the paper cushioning generation device for aligning a generated paper cushion into a predefined storage position and / or orientation. The alignment unit can contribute to further process stabilization by reinforcing the assumption of a predefined position and / or orientation of the paper cushion. The alignment device can, for example, comprise or interact with an optical device, such as a camera or the like, and / or sensors.

[0041] According to a further exemplary embodiment of the present invention, the packaging material processing station further comprises a material supply, arranged, in particular attached, to a housing of the packaging material processing station, comprising at least one paper packaging material web wound into a roll or folded into a fanfold stack. Due to the presence of a material supply, the packaging material processing station thus formed can operate autonomously for a certain period of time, until the material supply is exhausted, without the need for reloading, and can handle paper cushions, in particular for filling a transport container to be padded.

[0042] According to a further aspect of the present invention, which can be combined with the preceding aspects and exemplary embodiments, a method is provided for operating a packaging material processing station designed according to one of the previously described aspects and / or exemplary embodiments, in particular for filling a cavity in a transport container, in particular one occupied with a shipping item, with at least one paper cushion.

[0043] Preferred embodiments are specified in the subclaims.

[0044] In the following, further properties, features and advantages of the invention will become clear by describing preferred embodiments of the invention with reference to the accompanying exemplary drawings, in which:

[0045] Figure 1 is a perspective front view of an exemplary embodiment of a packaging material processing station according to the invention;

[0046] Figure 2 is a perspective rear view of the packaging material processing station of Figure 1;

[0047] Figure 3 A perspective detail view from the front of the packaging material processing station according to Figures 1 and 2;

[0048] Figure 4 is a further perspective view of the packaging material processing station from Figures 1 to 3;

[0049] Figure 5 shows an exemplary embodiment of a gripping device of a robot of the packaging material processing station from Figures 1 to 4; and Figure 6 shows a schematic representation of the gripping device from Figure 5 with a paper cushion.

[0050] In the following description of exemplary embodiments of the present invention, a packaging material processing station according to the invention is generally provided with the reference number 1. The packaging material processing station 1, which can also be referred to as a paper cushioning processing station, is designed according to the exemplary embodiments as a self-sufficient or automated station, in particular a robot cell, which, starting from a material supply 3, which according to Figure 2 comprises several starting material webs made of paper laid out on a pallet 7 and folded into a leporello stack 5, produces a three-dimensional, cushioning and dampening paper cushion 9 and places it in a transport container 11 that is empty or already filled with a shipping item to be shipped and packaged.The packaging material processing station according to the invention is thus fundamentally capable of padding transport containers 11, which are either filled with a shipping item or are still empty and are conveyed to station 1 by means of a transport device 13, with a paper cushion 9 produced by station 1 and finally of conveying the padded transport container 11 or alternatively the transport container 11 provided with a paper cushion 9 via the transport device 13 to a downstream processing station.

[0051] The packaging material processing station 1 according to the invention essentially comprises the following main components: a paper cushioning production or

[0052] A paper cushioning supply device 15 designed to produce a three-dimensional, cushioning paper cushioning product 9 from the paper starting material provided in web form in the form of the accordion stack 5; a robot 17 for gripping the paper cushion 9 produced by the paper cushioning production device 15 and placing the paper cushion 9 into a transport container 11; and a housing 19 that essentially encloses the components of the robot cell and has, on the one hand, a housing function and, on the other hand, a carrying or supporting function for the individual components. Furthermore, the housing 19 can have or be additionally provided with protective means for occupational safety, such as viewing windows, viewing grilles, or light barrier curtains, to prevent unintentional intrusion or intervention into the machine's danger zone.

[0053] As can be seen in Figure 1, a conveying direction F defined by the transport device 13 is oriented transversely, in particular perpendicularly, to an arrangement forming a cushioning supply line, each comprising a paper cushioning production device 15 and a robot 17. The transport device 13, which comprises a plurality of conveyor rollers 21 arranged successively in the conveying direction F, extends transversely through the housing 19 of the packaging material processing station 1 and comprises a conveyor section 23 which is enclosed in the housing 19.

[0054] Referring to Figure 2, which shows the rear view of the packaging material processing station 1 from Figure 1, the material supply 3 is shown with a plurality of fanfold stacks of folded paper starting material webs, which are arranged in the immediate vicinity of the paper cushioning device 15 for loading the latter. The housing 19 has an insertion area 25 on the rear side for receiving the material supply 3. This insertion area is designed to receive the material supply 3 and is accessible, for example, for a forklift or the like, so that the pallet 7 with the fanfold stacks 5 of starting material can be provided in this area.

[0055] Referring to Figure 3, which shows a detailed section of Figure 1, the mode of operation of the packaging material processing station 1 according to the invention is illustrated. Figure 3 also shows that the packaging material processing station 1, according to the preferred embodiments, comprises two independent cushioning supply lines, each with a cushioning production device 15 and a robot 17. The cushioning supply devices 15 each have a discharge designed as a discharge opening 27, at which the produced paper cushion 9 leaves the paper cushioning supply device 15. The robot 17 is assigned to the paper cushioning supply device 15 such that the robot 17 can remove, in particular pull, the produced paper cushion 9 directly at the exit 27 from the paper cushioning supply device 15.The paper cushioning supply device can be designed such that the paper cushions 9 do not leave the paper cushioning supply device 15 exclusively under the influence of the weight force, but are at least partially located in the region of the discharge opening 27.

[0056] In order to establish a predefined deposit position, which simultaneously serves as a gripping position for the robot 17, deposits 29 are arranged downstream of the paper cushioning supply device 15 and in particular of the discharge openings 27, said deposits providing a receiving space for the paper cushions 9 that is essentially U-shaped in cross-section and, for example, formed by two L-shaped sheet metal parts arranged at a distance from one another. The robots 17 comprise a plurality of articulated arms 31 that are connected to one another in an articulated manner, so that the robot 17 can move and rotate particularly flexibly in order to be able to carry out the desired cushioning process, namely grasping a produced paper cushion from the deposit 29 and inserting the paper cushion 9 into the transport container 11.

[0057] Advantageously, the produced paper cushion 9 is placed on the storage unit 29 at a predetermined position so that the robot 17 can grasp the paper cushion 9 reliably and reproducibly without additional position-detecting sensors. Furthermore, an end region of the produced paper cushion 9 can also be assigned to a predetermined position. The predetermined position can be formed, for example, by the cutting blade of the paper cushion generating device 15 for cutting off the produced paper cushion 9. Another predetermined position is formed by a delivery point or delivery region of the paper cushion generating device 15. A further predetermined position can be formed by a contact point of the storage unit 29, at which the produced paper cushion 9 rests.Advantageously, the predetermined positions form a reference point for the robot as a position orientation for at least one of the two end regions of the paper cushion 9 for the purpose of safe handling, without the need for additional position-detecting sensors. At a front gripper-side end, the robot 17 comprises a gripper bar 33, on which, according to the exemplary embodiment from the figures, two gripping devices 35 are arranged distally to one another, which, according to the exemplary embodiments, as can be seen in particular in Figures 5 and 6, are designed as needle grippers. Referring to Figures 5 and 6, the needle gripper is shown enlarged and comprises a plurality of needles 41 extending transversely to one another or oriented transversely to one another and movable in this direction, which needles can shear past one another to hook onto the paper cushion to be gripped. This is shown schematically in Figure 6.

[0058] The gripper bar 33 is further configured as a rigid element. The at least one needle gripper or the at least one gripping device 35 is attached to it. In one embodiment of the gripper bar 33, a fastening section is provided for fastening the needle gripper or for fastening the gripping device 35. This fastening section, in turn, is mounted on the rigid gripper bar 33 in an articulated and / or spring-loaded manner. If the paper cushion 9 has pronounced unevenness, at least in the gripping area, a spring-loaded and / or mechanical flexibility is thus created, which ensures and prevents only a predetermined force from acting on the paper cushion 9 when gripped by the needle gripper.According to another embodiment, the gripper bar 33 itself is designed as a spring-flexible element or has spring-flexible sections, wherein the respective needle grippers or the respective gripping device 35 is fastened in a region on the gripper bar 33 with a high spring deflection.

[0059] Referring again to Figure 3, the mode of operation of the packaging material processing station 1 according to the invention becomes clear. The robot 17 shown on the left in Figure 3, i.e. upstream with respect to the conveying direction of the transport device, grasps a paper cushion 9 produced by the left paper cushioning provision device 15, the robot 17 shown on the right in Figure 3, i.e. downstream with respect to the conveying direction of the transport device, is already in the process of placing a paper cushion 9 produced by the right paper cushioning provision device 15 into the transport container 11 arranged between the two robots 17 as viewed in the conveying direction F. Both robots 17 are intended to load their respective paper cushions 9 into the same transport container 11, either to fill an empty carton or to cushion a transport container 11 already occupied with a shipping item.

[0060] The gripper bar 33 can further be provided with a cushion sensor 45 for detecting the paper cushion 9. The cushion sensor 45 can be connected to a controller of the packaging material processing station 1 and can detect the paper cushion 9 at least during gripping by the needle gripper or by the gripping device 35 and at least during transfer and transport of the paper cushion 9 from the storage area 29 to the transport container 11. The cushion sensor 45 is arranged between, preferably centrally between, the needle grippers 41 or between the gripping devices 35. Alternatively, a cushion sensor is arranged next to a nail gripper 41 or next to a gripping device 35.

[0061] A reflection light sensor can be used as the cushion sensor 45, which is connected to the controller and provides it with a logical switching signal. Furthermore, at least one spacer 43 can be provided alongside the cushion sensor 45. This spacer extends from the sensor's detecting optics toward the paper cushion 45 and is constructed in such a way that any unevenness in the paper cushion is always kept at a distance from the detecting optics of the cushion sensor 45, whereby this distance is greater than the minimum switching distance of the cushion sensor 45. This ensures that a paper cushion to be detected is located within the detection range of the cushion sensor 45.

[0062] Referring to Figure 4, an enlarged perspective view from below of the packaging material processing station 1 is shown. This shows how the robots 17 are attached to the housing 19. For this purpose, a mounting plate 37 is attached to an underside of the housing 19 for each robot 17. A rigid base 39 is in turn attached to the mounting plates 37 for each robot 17, relative to which the respective adjoining upper articulated arm 31 can rotate. The mounting plate 37 is part of a rail system by means of which the robot 17 can be moved out of the housing 19 and into an assembly area outside the housing 19. In the event of repair, maintenance, or replacement of components of the robot 17, work on the robot 17 can thus be carried out outside the housing 19, whereby the regular operation of the packaging material processing station 1 can continue, albeit at a reduced speed.Advantageously, in the event of a robot failure, there is no downtime of the packaging material processing station 1.

[0063] The same applies to every component of every paper cushioning supply line. If, for example, a paper cushioning device 15 fails because it requires maintenance or because a paper jam needs to be cleared, this can also be done outside the housing 19, but at least outside the danger zone. For this purpose, the paper cushioning device 15 can be provided with a mount so that the paper cushioning device 15 is designed to be pivotable and / or displaceable relative to the housing 19. It is thus possible, for example, to remove a paper cushioning device 15 from the housing 19 for maintenance purposes.

[0064] The features disclosed in the above description, the figures and the claims may be important both individually and in any combination for the realization of the invention in the various embodiments.

[0065] List of reference symbols

[0066] 1 packaging material processing station

[0067] 3 Material stock

[0068] 5 leporello stacks

[0069] 7 pallets

[0070] 9 paper cushions

[0071] 11 transport containers

[0072] 13 Transport device

[0073] 15 Paper cushioning device

[0074] 17 robots

[0075] 19 housings

[0076] 21 transport rollers

[0077] Section 23

[0078] 25 Insertion or loading area

[0079] 27 Discharge opening

[0080] 29 filing

[0081] 31 Articulated arm

[0082] 33 gripper bars

[0083] 35 gripping device

[0084] 37 Mounting plate

[0085] 39 Base

[0086] 41 needle

[0087] 43 spacers

[0088] 45 Upholstery sensor

[0089] F Conveying direction

Claims

CLAIMS 1. Packaging material processing station (1) comprising a Paper cushioning production device (15) with a discharge (27) from which a produced paper cushion (9) can be removed, and a robot (17) which is assigned to the paper cushioning production device (15) in such a way that the robot (17) can remove the produced paper cushion (9) from the paper cushioning production device (15) via the discharge (27).

2. Packaging material processing station (1) according to claim 1, wherein the paper cushion generating device (15) has a dispensing and / or cutting device upstream of the dispensing device (27) for dispensing and / or cutting a paper cushion and is designed such that a produced paper cushion (9) does not leave the paper cushion generating device (15) exclusively under the influence of the weight force.

3. Packaging material processing station (1) according to claim 2, wherein the dispensing and / or cutting device and the dispensing device (27) are arranged in relation to one another and / or a length of the paper cushion to be produced is selected, in particular set, in such a way that a produced paper cushion (9) protrudes from the dispensing device (27) by at least 2 cm, in particular at least 3 cm, 4 cm or at least 5 cm.

4. Packaging material processing station (1), in particular according to one of the preceding claims, comprising a paper cushion producing device (15) with a dispenser (27) from which a produced paper cushion (9) can be removed, and a robot (17) for gripping the produced paper cushion, which robot has a needle gripper.

5. Packaging material processing station (1) according to claim 4, wherein the needle gripper has at least two, preferably a plurality of, needles and a gripping state in which the needles are extended, and a rest state in which the needles are retracted.

6. Packaging material processing station (1) according to claim 4 or 5, wherein 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 in such a way that the needles shear past each other.

7. Packaging material processing station (1) according to one of claims 4 to 6, wherein the needles, when assuming the rest state, retract in particular into a housing of the needle gripper in such a way that a paper cushion (9) gripped by the needles is stripped off in order to release the paper cushion (9).

8. Packaging material processing station (1), in particular according to one of the preceding claims, comprising at least two mutually independent paper cushion supply lines, each with a paper cushion production device (15) and a robot (17) for gripping a produced paper cushion from the respective paper cushion production device.

9. Packaging material processing station (1) according to claim 8, wherein the two paper cushioning supply lines are coordinated with one another in such a way that a paper cushion (9) of one paper cushioning supply line is produced at a different time than a paper cushion (9) produced by the further paper cushioning supply line and / or a produced paper cushion (9) is gripped by the robot (17) of one paper cushioning supply line at a different time than a produced paper cushion (9) by the further robot (17) of the other paper cushioning supply line.

10. Packaging material processing station (1), in particular according to one of the preceding claims, comprising a paper cushion producing device (15) with a delivery (27) from which a produced paper cushion (9) can be removed, a robot (17), and a storage arranged downstream of the paper cushion producing device (15) and defining a predefined storage position for a produced paper cushion (9), from which the robot (17) can grasp the paper cushion (9).

11. Packaging material processing station (1) according to claim 10, wherein the storage is inclined relative to the horizontal, wherein in particular the storage is inclined starting from the delivery (27) and / or has a transfer interface facing the delivery (27), which is arranged at the vertical height of the delivery (27) for receiving a produced paper cushion, and a storage surface adjoining the transfer interface, the vertical height of which is reduced with increasing distance from the transfer interface.

12. Packaging material processing station (1) according to claim 10 or 11, wherein the storage has a concave and / or V- or U-shaped storage surface for placing a produced paper cushion.

13. Packaging material processing station (1) according to one of the preceding claims, wherein the robot (17) is a multi-axis and / or an articulated robot, wherein in particular the axes are designed as serial kinematics.

14. Packaging material processing station (1) according to one of the preceding claims, wherein the robot (17) has a robot head with a gripping device arranged thereon, which has at least two grippers arranged at a distance from one another, such as a finger and / or needle gripper, wherein in particular the robot (17) further comprises a controller which is set up to control the grippers with the same control signal for simultaneous handling of a paper cushion or with a different control signal for independent handling of a paper cushion.

15. Packaging material processing station (1) according to one of the preceding claims, further comprising a housing on which the paper cushioning production device (15) is mounted movably, preferably pivotably, in particular movable between a cushioning production position approaching the robot (17) and a passive position remote from the robot (17).

16. Packaging material processing station (1) according to one of the preceding claims, further comprising a housing in which the robot (17) and optionally a transport container (11) to be filled with a produced paper cushion (9) are accommodated and on which the paper cushion generating device (15) is arranged, wherein in particular the housing has fastening interfaces for mounting and supporting the paper cushion generating device (15) and / or the robot (9).

17. Packaging material processing station (1) according to one of the preceding claims, further comprising a transport device (13), such as a conveyor belt, for the particularly automated transport of the transport container, in particular with at least one item of shipping material inside, preferably into a container filling area accessible by the robot (17).

18. Packaging material processing station (1) according to one of the preceding claims, further comprising a control and a paper cushioning device, the Robot (17) and, if applicable, communication technology linking the conveyor belt, such as a CAN bus, for controlling operation of the packaging material processing station.

19. Packaging material processing station (1) according to one of the preceding claims, further comprising an alignment unit downstream of the paper cushion generating device (15) for aligning a produced paper cushion into a predefined storage position and / or orientation.

20. Packaging material processing station (1) according to one of the preceding claims, further comprising a material supply arranged, in particular fastened, on a housing of the packaging material processing station (1) with at least one paper packaging material web wound into a roll or folded in the form of a leporello stack.

21. Method for operating a packaging material processing station (1) designed according to one of the preceding claims, in particular for filling a cavity in a transport container (11), in particular one containing a shipping material, with at least one paper cushion.

Images