Ergonomically improved blank joining module

Abstract

The present invention relates to a feeder module for a blank joining module. The feeder module includes an upper feeder device and a lower feeder device. Each feeder device includes a placement surface configured to receive a stack of blanks. Each feeder device is configured to discharge the blanks one by one in a conveying direction. The upper feeder device is displaceable in the conveying direction such that the upper placement surface is horizontally offset with respect to the lower placement surface.

Description

Technical Field

[0001] The present invention relates to a converting machine for manufacturing folding boxes and similar packaging containers. More specifically, it relates to a blank joining module configured to join two blanks before integrally folding the blanks.

Background Art

[0002] Converting machines such as folder-gluers are used in the manufacture of packaging items such as cardboard boxes and corrugated boxes. These machines include a plurality of workstations capable of folding, gluing a blank to form a box, and then counting, stacking, and adjusting the boxes into batches.

[0003] A folder-gluer can be configured to manufacture many different types of folding boxes and packaging containers. One type of assembled box formed by joining two blanks is sometimes called a "shelf-ready" box. A shelf-ready box includes an outer blank and an inner blank adhered together. The inner blank functions as a container for the merchandise to be stored, and the outer blank can function as protection during transportation. This type of box is commonly used in supermarkets and stores, and the inner container is placed on the shelf with the merchandise inside.

[0004] When manufacturing a packaging container by joining a plurality of blanks, a blank joining module with a double feeder is required. Specifically, each of the first blank and the second blank requires a dedicated feeder. An example of a blank joining module with an upper feeder and a lower feeder is described in European Patent Application Publication No. 2072241.

[0005] For large work batches, the machine operator needs to continuously place new blanks in the form of stacks on the upper and lower feeders. When the blank on the lower feeder has a significant horizontal length in the blank conveying direction, it is difficult for the machine operator to access the upper feeder.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] In view of the prior art, an object of the present invention is to provide a blank joining module that is easy to access the feeder.

Means for Solving the Problems

[0008] According to a first aspect of the present invention, there is provided a blank joining module for a converter, the blank joining module comprising an outer frame, an upper feeder device having an upper placement surface, and a lower feeder device having a lower placement surface, each feeder device being configured to receive a stack of blanks and discharge the blanks one by one in the conveying direction, and the upper placement surface of the upper feeder device being displaceable in the conveying direction such that the upper placement surface is horizontally offset with respect to the lower placement surface.

[0009] The present invention is based on the recognition that an upper feeder device having a displaceable placement surface enables improved lateral access to the upper feeder, and that access can be optimized for different formats of upper and lower blanks.

[0010] The conveying direction is horizontal. The conveying direction extends between the inlet and the outlet of the converter. The upper blank has an inclined conveying direction, and the lower blank has a horizontal conveying direction.

[0011] The horizontal conveying direction of the lower blank may include a deviation between 0 degrees and 15 degrees from the horizontal plane. The conveying direction of the upper feeder device includes a vertical component and a horizontal component. When the upper mounting surface is displaced, a horizontal displacement component occurs in the conveying direction. However, due to the inclined conveying path, the upper feeder device is also displaced in the vertical direction. Therefore, the horizontal displacement component of the upper mounting surface can displace the upper mounting surface upstream and downstream in the conveying direction.

[0012] The horizontal offset means that the upper mounting surface of the upper feeder device can be positioned further upstream in the conveying direction than the mounting surface of the lower feeder device. Thereby, the trailing edge of the upper mounting surface can be positioned to be horizontally offset from the trailing edge of the lower mounting surface. However, when the upper and lower blanks have different lengths in the conveying direction, this can align the trailing edge of the stack of the upper feeder device and the trailing edge of the stack of the lower feeder device in the vertical direction. The upper mounting surface can be moved upstream and downstream in the conveying direction. When the machine operator loads the upper and lower mounting surfaces from an upstream position, the upper mounting surface can be moved closer to the machine operator.

[0013] In one embodiment, the blank joining module further comprises an upper alignment device coupled to the upper feeder device, the upper feeder device having a variable length, and the upper feeder device being coupled to the upper alignment device. Preferably, there is a fixed coupling between the upper feeder device and the upper alignment device.

[0014] In one embodiment, the upper alignment device includes an upper pressing member and an upper conveyor belt configured to receive a blank therebetween, and the upper pressing member and the upper conveyor belt are supported by a common support structure, and the support structure includes an extensible and contractible connection mechanism configured to enable the longitudinal lengths of the upper pressing member and the upper conveyor belt to be changed integrally and by the same distance.

[0015] In one embodiment, the longitudinal lengths of the upper pressing member and the upper conveyor belt are changed simultaneously with the longitudinal displacement of the upper feeder device.

[0016] In one embodiment, the connection structure includes a plurality of frame members interconnected by pivot links, and the pivot links are configured to distribute the displacement of the upper feeder device into an equal-distance displacement between the frame members.

[0017] In one embodiment, the frame member includes a first cantilever extension and a second cantilever extension, the first cantilever extension is coupled to the pressing roller of the upper pressing member, and the second cantilever extension is coupled to a guide roller configured to maintain the shape of the upper conveyor belt.

[0018] In one embodiment, the feeder module includes a sliding rail coupling portion located between the upper feeder device and the outer frame.

[0019] In one embodiment, the blank joining module further includes a control circuit and a displacement motor, the control circuit is configured to determine the required longitudinal position of the upper feeder device based on the longitudinal length of the lower blank in the lower feeder device, and the displacement motor is configured to automatically displace the upper feeder device to a position horizontally offset with respect to the lower feeder device.

[0020] In one embodiment, the blank joining module further comprises an adjustable podium that is attached to the outer frame and movable in the conveying direction, the podium comprising at least one first step surface that is movable between an extended position located in front of the feeder device and a retracted position in which at least one step surface is located below the feeder device.

[0021] In one embodiment, the podium further comprises a second step surface, the second step surface being coupled to the first step surface by a sliding rail coupling, the second step surface being movable in a direction orthogonal to the conveying direction.

[0022] In one embodiment, the podium is locked in the extended configuration upon actuation of the locking mechanism.

[0023] In one embodiment, the locking mechanism is manually actuated by a push button and automatically actuates when the push button is released.

[0024] In one embodiment, the podium is coupled to a drive motor and the operator can extend and retract the podium by automatic displacement from the drive motor.

[0025] Hereinafter, the present invention will be described with reference to the accompanying drawings in which like reference numerals are assigned to like features.

Brief Description of the Drawings

[0026]

Figure 1

Figure 2a

Figure 2b

Figure 3a

Figure 3b

Figure 3c

Figure 4

Figure 5

Figure 6

Figure 7a

Figure 7b

Figure 7c

DETAILED DESCRIPTION OF THE INVENTION

[0027] Specifically, refer to FIG. 1 showing the converter 1 in the form of the folding-gluing machine 1. The folding-gluing machine 1 is configured to receive the upper stack S1 and the lower stack S2 of the blanks 2, join them, and fold and bond them together to form the folding box 2” or other assembled packaging containers.

[0028] There are several types of boxes 2’ and packaging containers that can be manufactured by the folding-gluing machine 1. One type of such box 2” is shown in FIGS. 2a and 2b and may be called the “shelf-ready” box 2’. As shown in FIG. 2b, this type of box 2’ is composed of two blanks 2b, 2a joined together. One blank 2a may form the inner container and the other blank 2b may form the outer container. In use, the outer container can be manually removed, while the inner container holds the goods.

[0029] This type of assembled folding box 2” is first manufactured by forming a blank 2’ assembled from a first blank 2a and a second blank 2b on a folding-gluing machine 1. Subsequently, the assembled blank 2’ undergoes folding and gluing operations.

[0030] As shown in Figure 1, this folding-gluing machine 1 comprises a series of different workstations in the form of modules. The modules can include a blank joining module 10, a folding pre-braking module 12, a gluing module 15, and a folding module 16 in the conveying direction T from an inlet A to an outlet B. The folding-gluing machine 1 can further include a main user interface 11 and a quality control system 18. After the gluing module and the folding module, a delivery module and an adjustment section 20 can be provided to count the roof plate-like flow of the folding box 2’’ and separate it into separate batches. The converter 1 further comprises a conveying system 19 including conveyors such as endless belts and rollers configured to convey the first and second blanks 2a, 2b in the conveying direction T. The converter 1 also comprises a control circuit 80 configured to control the operation of the blank joining module 10.

[0031] The blank joining module 10 enables the folding-gluing machine 1 to manufacture the assembled blank 2’. As shown in Figures 3 and 4, the blank joining module 10 comprises a feeder unit 32, an alignment unit 34, a gluing device 100, a positioning control configuration 36, and a joining transfer machine 38.

[0032] The feeder unit 32 comprises a lower feeder device 32a and an upper feeder device 32b. The upper feeder device 32b and the lower feeder device 32a are each configured to supply the blanks 2a, 2b one by one in the conveying direction T.

[0033] The upper feeder device 32b is configured to supply a first blank 2b, also referred to as an "upper blank" 2b, from a stack S2 disposed on the upper placement surface 33b. The lower feeder device 32a is configured to supply a second blank 2a, also referred to as a "lower blank" 2a, from a stack S1 disposed on the lower placement surface 33a of the lower feeder device 32a.

[0034] The upper placement surface 33b is located vertically above the lower placement surface 33a. To facilitate access to the upper placement surface 33b, the placement surface 33b of the upper feeder device 32b is displaceable in the longitudinal direction L, and thus in the conveyance direction T of the upper blank 2b. The longitudinal direction L is defined by the longitudinal extension of the upper placement surface 33b. Accordingly, the longitudinal direction L is inclined downward in the conveyance direction T.

[0035] The upper placement surface 33b can be displaced to a position horizontally offset with respect to the lower placement surface 33a. Thereby, the trailing edge of the blank 2b on the upper placement surface 33b can be vertically aligned with the trailing edge of the blank 2a on the lower placement surface 33a. Alternatively, the trailing edge of the upper blank 2b can be moved further upstream in the conveyance direction T, such that the horizontal distance between the trailing edge of the upper blank 2b and the trailing edge of the lower blank 2a is reduced. In this way, the upper placement surface 33b can be arranged closer to the machine operator.

[0036] As can be best seen from FIGS. 3a, 4, and 5, the upper feeder device 32b is slidably attached to the outer frame (i.e., the structural frame) 40 of the blank joining module 10. The coupling between the upper feeder device 32b and the outer frame 40 can be achieved by a sliding coupling. The sliding coupling can include a slide rail 42 and a slider 41. The upper feeder device 32b can be displaced along the slide rail 42 by a motor 44.

[0037] The motor 44 can automatically displace the upper feeder device 32b. The control circuit 80 of the blank joining module 10 can automatically operate the motor 44 to displace the upper feeder device 32b to a predetermined operating position calculated from the longitudinal length La of the lower blank 2a in the lower feeder device 32a. The longitudinal length La is the length of the lower blank 2a in the conveying direction T. Preferably, the upper feeder device 32b is displaced so that the trailing edges (in the conveying direction T) of the upper and lower stacks of the blank 2 in the respective feeder devices 32a and 32b are vertically aligned. Alternatively, the upper feeder device 32b can be displaced based on a manual input to the main user interface 11. In this way, the operator can determine the position of the upper feeder device 32b.

[0038] As shown in FIG. 4, the alignment unit 34 is arranged on the downstream side in the conveying direction T of the feeder unit 32. The alignment unit 34 is configured to horizontally align the upper blank 2b and the lower blank 2a to their respective predefined lateral positions. The predefined lateral positions are defined by the position of the longitudinal fold line 4 and the position of the folding tool in the converter 1. Accordingly, the predefined lateral positions can position the assembled blank 2' according to the assembly instructions, and the converter 1 is configured to fold the assembled blank 2' along the fold line 4.

[0039] Therefore, the alignment unit 34 is configured to align the upper and lower blanks 2b and 2a in a direction perpendicular to the conveying direction T. In this way, when the blanks 2a and 2b are brought into contact with each other at the joining point J, the upper blank 2b and the lower blank 2a are in the correct lateral positions.

[0040] The pasting device 100 is arranged on the upstream side of the joint point J. The pasting device 100 is arranged to distribute paste onto the upper surface of the lower blank 2a, and the paste is positioned therebetween when the upper and lower blanks 2b and 2a are brought into contact with each other.

[0041] The alignment unit 34 includes an upper alignment device 34b configured to align the upper blank 2b and a lower alignment device 34a configured to align the lower blank 2a. The upper and lower alignment devices 34b and 34a preferably include respective distal upstream coupling ends 35b and 35a fixedly coupled to the upper and lower feeder devices 32b and 32a.

[0042] The lower alignment device 34a is configured to convey the lower blank 2a along a substantially horizontal conveyance path Pa. Accordingly, the horizontal conveyance path may be offset between 0 degrees and 15 degrees with respect to the horizontal plane. As best seen from FIG. 6, the lower alignment device 34a includes an upper pressing member 60a, a lower conveyor 61a, and a guide (not shown). The lower conveyor 61a is composed of an endless conveyor belt 62a having a contact length Lca configured to contact the lower blank 2a and send the lower blank 2a forward in the conveyance direction T.

[0043] As best seen from FIGS. 7a-7c, the upper alignment device 34b includes an upper pressing member 60b and an upper conveyor 61b. The upper conveyor 61b includes an upper endless conveyor belt 62b having a contact length Lcb configured to contact the upper blank 2b and send the upper blank 2b forward in the conveyance direction T. The guide 63 is arranged with its extension portion aligned with the longitudinal direction. The upper pressing member 60b and the upper conveyor 61b are arranged at a predetermined angle with respect to the conveyance direction T so as to direct the lateral edge portion of the lower blank 2a toward the guide 63.

[0044] Therefore, the upper alignment device 34b is configured in the same manner as the lower alignment device 34a. However, the upper alignment device 34b has a contact length Lcb that is variable in the transport direction T. The upper alignment device 34b can further include a compensation mechanism 39 within the return path Pr of the upper conveyor belt 62b. The compensation mechanism 39 is configured to change the length of the upper endless conveyor belt 62b of the return path so as to correspond to the change in the contact length Lcb.

[0045] The upper alignment device 34b includes a movable distal end 35b coupled to the upper feeder device 32b and a fixed distal end 37b coupled to the structural frame 40 of the alignment device 34b. Accordingly, the movable distal end 35b is movable in the transport direction of the upper blank 2b. The outer frame 43 of the upper alignment device is coupled to the outer frame of the blank joining module 10. This enables displacement in the longitudinal direction L of the upper feeder device 32b while maintaining a fixed connection to the upper alignment device 34b.

[0046] As shown in FIGS. 7b and 7c, the upper conveyor 61b of the upper alignment device 34b further includes a support structure 69 configured to support the upper conveyor belt 62b. The support structure 69 includes a plurality of guide rollers 67 on which the upper conveyor belt 62b is mounted (see FIG. 7a). The guide rollers 67 are attached to the frame member 70. The connecting mechanism 68 connects adjacent frame members 70 to each other. The connecting mechanism 68 is extensible so as to be able to change the distance between the frame members 70. The frame member 70 is displaceable in the transport direction T. Each guide roller 67 is attached to the frame member 70 and arranged in a row. The connecting mechanism 68 can change the contact length Lcb as long as all the guide rollers 67 contact the upper blank 2b. The contact length Lcb can vary between the contracted position Lcb_min where the connecting mechanism 68 has the shortest length and the extended position where the connecting mechanism 68 has the longest length Lcb_max.

[0047] Preferably, the connecting mechanism 68 includes a plurality of pivotable links 74a, 74b that enable equidistant displacement of the frame member 70. The pivotable connecting links 74a, 74b can be provided by two linear elements. The pivotable connecting links 74a, 74b are coupled to each frame member 70 at a central pivot 75. Also, the pivotable connecting links 74a, 74b are coupled to each other at an upper pivot 76 and a lower pivot 77. The upper pivot 76 and the lower pivot 77 are movable in the longitudinal direction L.

[0048] By coupling the frame member 70 to the central pivot 75, the horizontal position of the central pivot 75 is kept constant.

[0049] The support structure has a first distal end 35b coupled to the upper feeder device 32b and a second distal end 37b coupled to the outer frame 40 of the blank joining module 10.

[0050] As best seen from FIG. 7c, each frame member 70 includes a first cantilever extension 70a, a second cantilever extension 70b, and a frame member bracket 70c to which the first and second cantilever extensions are coupled.

[0051] The guide roller 67 of the upper conveyor belt 62b is attached to the first cantilever extension 70a, and the pressing roller 66 is attached to the second cantilever extension 70b. The upper blank 2b is received between the pressing roller 66 and the upper conveyor belt 62b. The first and second cantilever extensions 70a, 70b extend horizontally and parallel to each other. The second cantilever extension 70b is disposed vertically above the first cantilever extension 70a.

[0052] The second cantilever extension 70b can be supported by an upper guide rail 71b, and the second cantilever extension 70b can be supported by a lower guide rail 71a. Each of the guide rails 71a, 71b can be in the form of a longitudinal bar disposed below the first and second cantilever extensions 70a, 70b.

[0053] The distal inlet end 35b of the upper alignment device 34b can include a mounting bracket 79 configured to be attached to the upper feeder device 32b. The mounting bracket 79 can further include a fixed structure that forms an inlet section I for the upper pressing roller 66 and the guide roller 67 of the conveyor belt 62b. The mounting bracket 79 provides a fixed connection portion of the cantilever extensions 70b, 70c such that the inlet section I has a constant length regardless of the extension or contraction of the connection mechanism 68. This can ensure that there is a sufficiently long inlet section I to the upper alignment device 34b, and the upper blank 2b is adapted to fully exit the upper feeder device 32b before the upper blank 2b is obliquely aligned with the guide 63. The distal central pivot 79a is attached to the mounting bracket 79. A second distal central pivot 79b is attached to the frame member 77 of the upper alignment module 34b.

[0054] To further facilitate access to the upper feeder device 32b, the blank joining module 10 can further include a modular podium 50. As can be best seen from FIGS. 3a - 3c, the podium 50 includes at least a first step surface 52a. Preferably, the podium 50 includes a second step surface 52b disposed on the first step surface 52a.

[0055] Preferably, the second step surface 52b can be smaller than the first step surface 52a. The second step surface 52b can be coupled onto the first step surface 52a via a sliding rail coupling 56. The first step surface 52a is movable in the conveying direction T, and the second step surface 52b is movable in a direction orthogonal to the conveying direction T.

[0056] The first step surface 52a is provided with displacement means 53 and is adapted to be displaced between a retracted position RP (see Fig. 3a) located below the converter 1 and an extended position EP located in front of the converter 1. The displacement means 53 can be in the form of rollers or sliding rails. In the extended position EP, the first step surface 52a and the second step surface 52b are positioned such that an operator can stand on the first and second step surfaces 52a (52b) and be easily accessed by the mounting surface 33b of the upper feeder device 32b. Preferably, the first step surface 52a and the second step surface are provided with a locking mechanism 57. Thereby, the first and second step surfaces 52a, 52b can be locked in the extended position EP to reduce the risk of unexpected movement.

[0057] The first step surface 52a can be coupled to a drive mechanism comprising a displacement motor 54. The displacement means 53 and the drive mechanism are attached to the structural frame 40 of the blank joining module 10.

[0058] Manual displacement of the first step surface 52a can be initiated by actuating a push button 55 located on the handle of the modular podium 50. Alternatively, the first and second step surfaces 52a, 52b can be automatically displaced between the retracted position and the extended position based on information from the control circuit 80.

[0059] The modular podium 50 can cooperate with an upper extendable upper feeder device 32b. The upper feeder device 32b enables improved horizontal access to the upper feeder device 32b, and the podium enables improved vertical access to the upper feeder device.

Description of the reference numerals

[0060] 2a lower blank 2b upper blank 32a lower feeder device 32b upper feeder device Lower placement surface of 33a Upper placement surface of 33b Outer frame 40 Stack of S2 S1 stack T conveying direction

Claims

1. A blank joining module for a converter comprising an outer frame (40), an upper feeder device (32b) having an upper placement surface (33b), and a lower feeder device (32a) having a lower placement surface (33a), wherein the upper feeder device is configured to receive a stack (S2) of upper blanks (2b), the lower feeder device is configured to receive a stack (S1) of lower blanks (2a), the feeder devices (32a, 32b) are each configured to discharge one upper and lower blank (2a, 2b) at a time in a transport direction (T), and the upper placement surface of the upper feeder device is displaceable in the transport direction such that the upper placement surface is horizontally offset with respect to the lower placement surface. Blank joining module.

2. Further comprising an upper alignment device (34b) coupled to the upper feeder device, the upper alignment device having a variable length, and the upper feeder device being coupled to the upper alignment device. The blank joining module according to claim 1.

3. The upper alignment device includes an upper pressing member (60a) and an upper conveyor belt (62b) configured to receive a blank therebetween, and the upper pressing member and the upper conveyor belt are supported by a common support structure (69). The support structure includes an extendable and retractable connection mechanism (68) configured to enable the longitudinal lengths of the upper pressing member and the upper conveyor belt to be changed integrally and by the same distance. The blank joining module according to claim 2.

4. The longitudinal lengths of the upper pressing member and the upper conveyor belt are changed simultaneously with the longitudinal displacement of the upper feeder device. The blank joining module according to claim 3.

5. The connection structure includes a plurality of frame members (70) interconnected by pivot links (74a, 74b), and the pivot links are configured to distribute the displacement of the upper feeder device into an equal-distance displacement between the frame members. The blank joining module according to claim 4.

6. The frame member includes a first cantilever extension portion (70a) and a second cantilever extension portion (70b). The first cantilever extension portion is coupled to the pressing roller (66) of the upper pressing member, and the second cantilever extension portion is coupled to a guide roller (67) configured to maintain the shape of the upper conveyor belt (62b). The blank joining module according to claim 5.

7. The feeder module includes a sliding rail coupling portion located between the upper feeder device and the outer frame. The blank joining module according to any one of claims 1 to 6.

8. Further comprising a control circuit (80) and a displacement motor (44), the control circuit is configured to determine a required longitudinal position of the upper feeder device based on the longitudinal length (La) of the lower blank in the lower feeder device, and the displacement motor is configured to automatically displace the upper feeder device to a position horizontally offset with respect to the lower feeder device. The blank joining module according to any one of claims 1 to 7.

9. The blank joining module further includes an adjustable podium (50) attached to the outer frame and movable in the conveying direction. The podium includes at least one first step surface (52a), and the first step surface is movable between an extended position (EP) located in front of the feeder devices (32a, 32b) and a retracted position (RP) where the at least one step surface is located below the feeder devices (32a, 32b). The blank joining module according to any one of claims 1 to 8.

10. The podium further includes a second step surface (52b), the second step surface is coupled to the first step surface by a sliding rail coupling portion (56), and the second step surface is movable in a direction orthogonal to the conveying direction. The blank joining module according to any one of claims 1 to 9.

11. The podium is locked in an extended configuration when the locking mechanism (57) is actuated. The blank joining module according to claim 9 or 10.

12. The locking mechanism is manually actuated by a push button (55), and the locking mechanism is automatically actuated when the push button is released. The blank joining module according to claim 11.

13. The podium according to claim 12, which is coupled to a drive motor (54) and the operator can extend and contract the podium by an automatic displacement from the drive motor.

Images