Equipment and methods for packaging products
The use of a conveying system with speed- and position-controlled carriers addresses the inflexibility and inefficiency of existing packaging equipment for sanitary products by automating multiple process steps and enhancing production speed and accuracy.
Patent Information
- Application Number
- JP2024561672
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-04-27
- Filing Date
- 2023-02-02
- Publication Date
- 2025-05-02
AI Technical Summary
Existing packaging equipment lacks flexibility and efficiency in handling and packaging of sanitary products, such as diapers, panty liners, and sanitary napkins, as it often requires manual intervention and limited automation for process steps like stacking, folding, and sealing.
A conveying system with independently and simultaneously speed- and position-controlled carriers is used to move and manipulate individual products and packaging materials through multiple process steps, allowing for flexible configuration of process flow and automation of tasks like stacking, folding, and sealing.
The solution enables high flexibility and efficiency in packaging sanitary products by automating multiple process steps, reducing manual intervention, and allowing for parallel processing of tasks, thereby increasing production speed and reducing errors.
Smart Images
Figure 2025514061000001_ABST
Abstract
Description
[Technical field]
[0001] The present invention relates to an apparatus and a method for packaging products, in particular hygiene products such as diapers, panty liners, sanitary napkins, incontinence products, wet wipes, toilet paper, kitchen rolls and the like. [Background technology]
[0002] The products to be packaged are usually taken from a stock or a production line as individual products and integrated into a packaging unit comprising a packaging material and a number of individual products at least area-wise surrounded by the packaging material. The individual products, the unit comprising the number of individual products and / or the packaging unit are suitably processed in one or more process steps, e.g. the individual products are turned, folded, inspected, integrated into stacks or groups comprising a number of stacks, the unit comprising the number of individual products is fed into a packaging material, the packaging material is sealed, labeled, printed and the packaging unit is released.
[0003] Various devices are known for handling and / or transporting products in or between process steps. For example, from EP 1 663 823 B1, a row-forming device for forming stacks from continuously supplied individual products is known, which comprises a number of compartments which are moved along a closed path, into which one product is inserted in each case and from which stacks of products are then pushed out of adjacent compartments. From EP 1 670 706 B1, a transport device is known, which receives loosely supplied products in pockets and feeds these to a row-forming device having compartments. During feeding, the products receive a velocity component in the direction of movement of the compartments, while the products are braked to a stop in the previous direction. Summary of the Invention [Problem to be solved by the invention]
[0004] The object of the present invention is to provide a highly flexible installation and method for packaging products, in particular hygiene products such as diapers, panty liners, sanitary napkins, incontinence products, wet wipes, toilet paper, kitchen rolls, etc. [Means for solving the problem]
[0005] The above problem is solved by an installation having the features of claim 1 and by a method having the features of claim 6. Further advantageous embodiments emerge from the dependent claims.
[0006] According to a first aspect, there is provided an installation for packaging products, in particular hygiene products such as diapers, panty liners, sanitary napkins, incontinence products, wet wipes, toilet paper, kitchen rolls, etc., configured to integrate individual products in a number of process steps into a packaging unit comprising a packaging material and a number of individual products at least area-wise surrounded by the packaging material, the installation comprising a conveying system having a conveying surface, a number of conveyors and a control device, the control device being configured to control actuators of the conveying surface and / or the conveyors, whereby the conveyors are moveable relative to the conveying surface independently of one another and simultaneously with speed and / or position control, and at least some of the conveyors are configured to move individual products and / or groups comprising a number of individual products for transport between two process steps and / or to move and / or manipulate individual products and / or groups comprising a number of individual products and / or packaging material in at least one process step.
[0007] According to a second aspect, there is provided a method for packaging products, in particular hygiene products such as diapers, panty liners, sanitary napkins, incontinence products, wet wipes, toilet paper, kitchen rolls, wherein individual products are integrated in a plurality of process steps into a packaging unit comprising a packaging material and a plurality of individual products at least areawise surrounded by the packaging material, and the individual products and / or the group comprising the plurality of individual products and / or the packaging material are handled and / or moved for transport in at least one process step and / or between two process steps by a transport body which is moved relative to a transport surface in a speed-controlled and / or position-controlled manner, the transport body and the transport surface being part of a transport system comprising a transport surface and a transport body which can be moved relative to the transport surface in a controlled manner independently and simultaneously of each other.
[0008] Terms such as "one" are used only as specific terms in the context of the present application and not as numerals. In particular, in one embodiment, it is contemplated that the individual products and / or groups comprising multiple individual products are handled and / or moved by two or more transport bodies moved in a speed-controlled and / or position-controlled manner relative to the transport surface for transport in a process step and / or between two process steps. Similarly, in one embodiment, multiple transport surfaces are provided, which have different orientations.
[0009] Actions on individual products, groups thereof or packaging that change their state, for example by rotating, moving, folding, compacting, erecting cartons, etc. are referred to as manipulations of the individual products or groups of individual products and / or packaging. In the context of this application, any step referred to as a process step includes, when packaging a product, process steps for handling the individual products, such as manipulations of the individual products by rotating, moving, folding, compacting, etc., process steps for process inspection, such as weighing, process steps for stacking or grouping the individual products or groups of individual products, process steps for adding, changing or removing material, etc.
[0010] A conveying system with a conveying surface and a carrier movable relative to it is also called a planar conveying system. In that case, the conveying surface is designed in the form of a stator. The carrier is movable with three degrees of freedom to change its position and orientation at least in a plane parallel to the conveying surface. In an advantageous embodiment, a six-degree-of-freedom movement of the carrier relative to the conveying surface is possible. This ensures a high level of flexibility. In an embodiment of the conveying system, the movement of the carrier relative to the conveying surface is performed in a contactless or floating manner. A corresponding conveying system is known, for example, from DE 102018209401 A1, which is incorporated herein in its entirety by reference. However, the present application is not limited to the use of the conveying system known from DE 102018209401 A1.
[0011] In one embodiment the conveying surface is arranged in a horizontal plane, however, alternatively or additionally, embodiments are envisaged in which a vertically arranged conveying surface is provided.
[0012] The use of such a transport system for the transport of individual products or groups of individual products in a packaging installation allows a flexible arrangement of the individual stations for performing process steps and a flexible configuration of the process flow. The individual stations for performing process steps can be selectively supplied with transport bodies or not. For example, selectively, in a process step, it is conceivable to add additional products to the packaging unit, and correspondingly, the transport bodies are selectively supplied to stations for performing a process step of adding the additional products. Alternatively or additionally, the individual products or groups of individual products can be supplied at regular or irregular intervals to an inspection station for process monitoring.
[0013] Alternatively or additionally, in one embodiment, it is contemplated that the groups of individual products are fed to different packaging stations where they are processed with different packaging materials. In one embodiment, it is further contemplated that feeding takes place to different closing stations, for example different welding stations, depending on the packaging material used and / or other process parameters. In that case, different closing stations can perform different process steps or the same process steps can be performed with different process parameters.
[0014] In one embodiment, it is contemplated that at least one process step can be performed in parallel at two or more stations. This allows the process flow to be at least partially parallelized in order to increase speed. In particular, for this purpose, in one embodiment, it is contemplated that the process step for closing the packaging is performed in parallel at two or more stations.
[0015] Furthermore, the installation can be flexibly adapted by adding or removing stations and / or by changing the location of individual stations.
[0016] Furthermore, the carrier may be repeatedly fed through the stations, for example to repeatedly perform a process step at different points in the process flow and / or to repeat a process step upon the occurrence of a defect.
[0017] In one embodiment, the carriers move on the transport surface at different speeds, thereby varying the distance between the carriers, and in one embodiment, it is contemplated that the distance may be increased for, for example, metal detector inspection, printing, and / or weighing.
[0018] At least a part of the carrier is configured to move the individual products and / or groups comprising a plurality of individual products for transport between two process steps and / or to move and / or manipulate them in at least one process step. For this purpose, in one embodiment, the carrier has suitable receiving, support and / or holding elements by which the individual products and / or groups of individual products are fixed on the carrier during transport. In one embodiment, the carrier has a suction or vacuum holding device for the transport of the individual products. Alternatively or additionally, the carrier has a cassette into which the individual products can be inserted. In one embodiment, the cassette has compartments, in which the individual products can be accommodated respectively. Alternatively or additionally, in another embodiment, a separate mobile cassette with or without compartments for the individual products is provided, which cassette can be moved between the stations by a carrier or by several carriers. In one embodiment, the installation comprises both a carrier with a cassette and several separate cassettes.
[0019] In one embodiment, it is contemplated that multiple transport items, i.e. multiple individual products, individual products and groups, and / or multiple groups, are transported by a transport body at least temporarily simultaneously, and process steps corresponding to each individual transport item are performed at the stations.
[0020] In one embodiment, it is intended that the carrier is provided with functional units for carrying out process steps. In that case, in the context of this application, a device for carrying out a process step, designed according to the process step, is called a functional unit. With the functional unit, it is then possible to carry out one process step or several process steps during the carrying of the carried object. In addition, the functional unit can be moved to different positions by the carrier in order to carry out process steps at different locations, either stationary or moving, by the functional unit. In that case, depending on the design of the functional unit, manipulation of the carried object and / or inspection of the carried object, for example weighing of the carried object, can be carried out on the carrier.
[0021] Alternatively or additionally, in one embodiment, it is contemplated that the weight of the load accommodated by the carrier is determined from the actuation force for controlling the conveying surface relative to the carrier. In other words, the load is weighed by the conveying system. In one embodiment, the weighing is performed for quality or defect inspection. For example, in one embodiment, the weight of the individual products is sensed upon pick-up of the individual products.
[0022] In one embodiment, the control device is configured to move two or more carriers in a coordinated manner relative to the conveying surface in order to perform a process step. The two or more carriers allow manipulation of the accommodated objects. In one embodiment, the movement is used for manipulation of the objects, for example for compacting, folding, correcting folding errors, etc. For example, in one embodiment, the two carriers can be moved relative to one another in order to compact or compress an object placed between them.
[0023] In another embodiment, the control device is configured to change the position and / or orientation of the carrier with the contained items relative to the conveying surface for a subsequent process step and / or to change the position and / or orientation of the carrier relative to the conveying surface to contain the items. In one embodiment, flat products, in particular flat hygienic products such as panty liners, sanitary napkins or diapers, are taken from the stock or production device in a lying state onto the carrier, and the carrier is controlled to change its orientation, so that the taken products are transferred in an upright position to a subsequent process step, for example for stacking. Thereby, a rotation step in the process step can be omitted. In another embodiment, flat products, in particular flat hygienic products such as panty liners, sanitary napkins or diapers, are taken from the stock or production device in a lying state onto the carrier, and are placed on top of each other on the carrier to form a stack, and the carrier is controlled to change its orientation after the stack size is reached in order to convey the stack away to the packaging material. Alternatively or additionally, it is contemplated that the carrier changes its position and / or orientation in order to pick up the product. In one embodiment, the change in position and / or orientation is used to brake the product being picked up. In another embodiment, the change in position and / or orientation is used to compensate for tolerances from a previous process step and / or to compensate for tolerances when picking up from a production facility. For example, it is conceivable to pick up a number of individual products onto the carrier such that, by suitable movement of the carrier, the individual products are aligned in a plane on the carrier. In another embodiment, the carrier is rotated, whereby the conveyed item is picked up in a first orientation and transferred in a second, different orientation.
[0024] In another embodiment, the control device is configured to feed two or more transports containing groups of individual products together to a subsequent process step, which can be used, for example, to store stacks of individual products and thus feed them to a device for packaging the stacks.
[0025] Further advantages and aspects of the invention emerge from the claims and from the description of exemplary embodiments of the invention which are set forth below with the aid of schematic drawings. [Brief description of the drawings]
[0026] [Figure 1] FIG. 1 shows an installation for packaging products in multiple process steps. [Diagram 2] FIG. 1 illustrates the process steps for picking and queuing products. [Diagram 3] FIG. 1 illustrates process steps for aligning products. [Figure 4] FIG. 1 illustrates process steps for compacting a stack of products. [Diagram 5] FIG. 1 illustrates process steps for reorienting a stack of products. [Figure 6] FIG. 1 illustrates process steps for grouping multiple stacks of products. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Fig. 1 shows an installation 1 for packaging products, in particular hygiene products such as diapers, panty liners, sanitary napkins, incontinence products, wet wipes, toilet paper, kitchen rolls, etc., by means of which the products are suitably processed or manipulated in eleven process steps 101, ..., 111. In the process steps 101, ..., 111, depending on the application, the individual products are turned, folded, inspected, consolidated into stacks or groups comprising several stacks, units comprising several individual products are fed into a packaging material, the packaging material is sealed, labelled, printed and the packaging unit is handed over.
[0028] The installation 1 comprises a conveying system 2 having a conveying surface 21, a number of conveyors 20 and a control device 22. The conveyors 20 can move with six degrees of freedom relative to the conveying surface 21, as indicated diagrammatically by the arrows.
[0029] In the exemplary embodiment shown in Fig. 1, the transport system 2 is used for the transport of individual products or groups of individual products to stations for carrying out process steps 101, ..., 111. For this purpose, in the illustrated exemplary embodiment, actuators of the transport surface 21 and / or of the transport bodies 22 are controlled by a control device 22 in order to move a plurality of transport bodies 20 independently of one another and simultaneously with speed and / or position control relative to the transport surface 21 for the transport of individual products and / or groups comprising a plurality of individual products between two process steps 101, ..., 111.
[0030] Control is provided such that the carrier 20 goes through, for example, process steps 102, 110, 103, 107, 106, 111, 105, 104, 101, 107. In the process flow shown in Figure 1, process steps 108, 109 are not performed. In other embodiments, these process steps 108, 109 are performed in addition to or instead of other process steps. In the process flow shown, process step 107 is performed twice, for example, after process steps 102, 110, and 103, and at the end of the process flow.
[0031] In the illustrated exemplary embodiment, all stations for performing process steps are arranged in the transport plane 21, except for the station for performing process step 103. However, this design is only schematic.
[0032] In the illustrated exemplary embodiment, the carriers 20 do not simply serve to transport the products. Rather, in process step 110, it is contemplated that the two carriers 20 are controlled to move relative to the conveying surface 21 when performing the process step, thereby causing the individual products to be manipulated, e.g., rotated, folded, and / or compressed, by the carriers 20. In one embodiment, it is also contemplated that more than one carrier 20 is manipulated for operation in one process step.
[0033] Further, in the illustrated exemplary embodiment, process step 111 occurs on carrier 20. In one embodiment, process step 111 may be performed during movement of carrier 20 between process steps 106 and 105.
[0034] It should be noted that the process flow shown in FIG. 1 is merely an example, and many variations are possible.
[0035] FIG. 2 shows a schematic top view of the process steps for taking over and arranging the individual products 3 in a stack 30. In the illustrated exemplary embodiment, a transport 20 is provided for this purpose with a cassette 4 which includes a number of compartments 40, each of which can accommodate an individual product 3. The individual products 3 are fed as a product stream in a first orientation, which is indicated generally by the arrow. In the illustrated exemplary embodiment, a rotating device 5 is provided, by means of which the orientation of the individual products 3 is changed. The illustrated rotating device 5 is arranged in a fixed position, and the transport 20 is movable in a direction I relative to the rotating device 5 in order to position the compartments 40 for taking over the individual products 3, respectively, relative to the rotating device 5. In an alternative embodiment, the rotating device 5 is omitted and the transport 20 with the appropriately oriented cassette 4 is moved perpendicularly to the plane of the drawing according to FIG. 2 in order to take over and arrange the individual products 3.
[0036] In one embodiment, the weighing is performed when the individual products 3 are taken up. In particular, in one embodiment, the weight of the individual products taken up by the carrier 20 is determined from the actuation force for controlling the conveying surface 21 for the carrier 20. Weighing the individual products 3 when they are taken up allows anomalies to be recognized early. In one embodiment, in the event of an anomaly, the associated carrier 20 is fed for an inspection which is carried out manually or automatically.
[0037] Furthermore, as shown diagrammatically by the double-headed arrow in Figure 2, when picking up the individual products 3, the conveying body 20 can be moved relative to the rotating device 5 in the supply direction of the individual products 3 in order to compensate for any offset between the individual products 3 in the product flow resulting from production.
[0038] In an alternative embodiment, unlike in figure 2, the transport body 20 does not move in the feed direction of the individual products 3. If alignment of the individual products 3 is required, this can be done in a subsequent process step, as shown diagrammatically in figure 3.
[0039] 3 shows diagrammatically the process steps for aligning a stack 30 of individual products 3 arranged on a carrier 20. The individual products 3 are initially randomly arranged in cassettes 4 arranged on the carrier 20. The carrier 20 reciprocates relative to the conveying surface 21, as indicated diagrammatically by the arrow, so that the individual products 3 are aligned with their downwardly facing edges with the bottoms of the cassettes 4. Depending on the embodiment, this movement takes place perpendicularly to the conveying surface 21 and / or with another directional component.
[0040] 4 shows diagrammatically the process steps for compacting a stack 30 of individual products 3 arranged on a carrier 20. The stack of individual products 3 is arranged in a cassette 4 arranged on the carrier 20. The cassette 4 has two adjustable walls 42 arranged at either end. To compact the stack 30, the two walls 42 are moved towards each other. In an alternative embodiment, an adjustable wall and a fixed wall are provided.
[0041] Two plungers 7 are provided for moving the walls 42. In one embodiment, the plungers 7 are provided in fixed positions at the stations and the carriers 20 with the stacks 30 of individual products 3 are moved between the plungers for compaction. In the embodiment shown, the plungers 7 are provided on each of the carriers 20 and the carriers 20 are moved relative to one another to compact the stacks 30.
[0042] In the illustrated exemplary embodiment, the carrier 20 with the plunger 7 is adjustable relative to the conveying surface 21. In an alternative embodiment, a second conveying surface is provided that is disposed perpendicular to the illustrated conveying surface 21, and the carrier 20 with the plunger 7 is adjustable relative to the second conveying surface.
[0043] In yet another embodiment, the plunger 7 is attached to the carrier 20 by structures, which allows the distance between the carrier 20 of the plunger 7 and the carrier surface 21 to be reduced while maintaining the height of the plunger 7.
[0044] FIG. 5 shows a schematic top view of a process step for changing the orientation of a stack 30 of individual products 3 arranged on a transport 20. The stack 30 of individual products 3 is arranged in a cassette 4 arranged on the transport 20. The orientation is such that initially a first end 31 of the individual products 3 is arranged in front of the transport direction, as indicated diagrammatically by the arrow, and a second end 32 is arranged behind. The terms "first" and "second" are used only for distinction and do not indicate an order. The transport 20 rotates about an axis extending perpendicular to the transport plane, so that after the rotation, the second end 32 of the individual products is arranged in front of the transport direction, as indicated diagrammatically by the arrow. The illustrated change of orientation is only an example, and many variations are possible.
[0045] 6 shows a schematic top view of process steps for grouping a plurality of stacks 30, each disposed on a carrier 20. In the embodiment shown in FIG. 6, the stacks 30 in the bottom row of the figure are uniformly oriented for grouping, while the stacks 30 in the top row of the figure are variously oriented, although this arrangement is by way of example only. In other embodiments, the stacks 30 are alternatively or additionally disposed at least partially offset from one another by 90°.
[0046] In one embodiment, it is further contemplated that the transport 20 may additionally be moved perpendicular to the transport plane to position the stacks 30 up or down during the process step of grouping multiple stacks 30 together.
[0047] In one embodiment, a group of stacks 30 according to Fig. 6 are fed in a subsequent process step, not shown, into a packaging material, e.g. a film bag, not shown. The stacks 30 are separated from the carrier 20. To separate the stacks from the carrier 20, in one embodiment, the carrier 20 is tilted so that the stacks 30 slide off the carrier 20. Additionally or alternatively, in one embodiment, the stacks 30 are pushed out using a suitable slider or similar element.
[0048] In one embodiment, after the stack 30 has been transferred, the carrier 20 is moved to a starting position for picking and lining up the individual products, for example according to the process steps shown in FIG.
[0049] In the embodiment shown in Figures 3 to 6, the carriers 20 each have a cassette 4 without compartments. In other embodiments, a carrier with a cassette 4 having compartments 40 similar to Figure 2 is provided for these or similar process steps.
[0050] In yet another embodiment, the carrier 20 does not have cassettes 4 for picking up and transporting the individual products 3. The individual products 3 are held on the carrier 20, for example based on gravity or by a suitable holding device.
[0051] The embodiment shown is merely exemplary and many variations are possible for the use of the planar conveying system 2 in an installation for packaging products.
Claims
1. An installation for packaging products, in particular hygiene products such as diapers, panty liners, sanitary napkins, incontinence products, wet wipes, toilet paper, kitchen rolls, etc., said installation being configured to combine the individual products (3) in a number of process steps (101, . . . , 111) into a packaging unit comprising a packaging material and a number of individual products (3) at least area-wise surrounded by said packaging material, The facility (1) includes a conveying system (2) having a conveying surface (21), a plurality of conveying bodies (20), and a control device (22); the control device (22) is configured to control actuators of the conveying surface (21) and / or the conveying bodies, whereby the conveying bodies (20) are movable relative to the conveying surface (21) in a speed-controlled and / or position-controlled manner independently and simultaneously of each other; At least a portion of the carrier (20) for moving an individual product (3) and / or a group comprising several individual products (3) for transport between two process steps (101, . . . , 111); and / or configured to move and / or manipulate individual products (3) and / or groups comprising a plurality of individual products (3) and / or said packaging material in at least one process step (101, . . . , 111); The facility is characterized by:
2. 2. Installation according to claim 1, characterised in that the carrier (20) is provided with functional units for carrying out process steps.
3. 3. The installation according to claim 1 or 2, characterized in that the control device (22) is configured to move two or more transport bodies (20) in a coordinated manner relative to the transport surface (21) to perform a process step.
4. The control device (22) and / or to change the position and / or orientation of the transport body (20) with the transported objects relative to the transport surface for a subsequent process step; and / or To accommodate the transported items, the position and / or orientation of the transport body (20) relative to the transport surface (21) is changed.
4. The installation according to claim 1, 2 or 3, characterized in that it is configured
5. Installation according to any one of claims 1 to 4, characterised in that the control device (22) is configured to feed two or more conveyors (20) containing groups of individual products (3) together to a subsequent process step.
6. A method for packaging products, in particular hygiene products such as diapers, panty liners, sanitary napkins, incontinence products, wet wipes, toilet paper, kitchen rolls, etc., comprising the steps of: The individual products (3) are integrated in a number of process steps (101, . . . , 111) into a packaging unit comprising a packaging material and a number of individual products at least area-wise surrounded by said packaging material, The individual products (3) and / or groups comprising a plurality of individual products (3) and / or said packaging material are handled and / or moved by a transport body (20) which is moved in a controlled manner relative to a transport surface (21) for transport in at least one process step and / or between two process steps, The method, wherein the conveying body (20) and the conveying surface (21) are part of a conveying system (2) comprising a conveying surface and a plurality of conveying bodies (20) movable relative to the conveying surface (21) independently and simultaneously in a speed- and / or position-controlled manner.
7. 7. A method according to claim 6, characterized in that the weight of the goods accommodated by a conveying body (20) is determined from the actuation force for controlling the conveying surface (21) for said conveying body.
8. 8. A method according to claim 6 or 7, characterized in that two or more carriers (20) are moved in a coordinated manner relative to the conveying surface (21) to perform a process step.
9. the position and / or orientation of the transport body (20) containing the transported objects relative to the transport surface (21) is changed in order to position and / or orient the transported objects for a process step; and / or 9. Method according to claim 6, 7 or 8, characterized in that for accommodation of the conveyed goods, the position and / or the orientation of the conveying body (20) relative to the conveying surface (21) is changed.
10. Method according to any one of claims 6 to 9, characterised in that two or more carriers (20) containing groups of individual products (3) are fed together to a subsequent process step.