Method and plant for manufacturing secondary packaging according to box-on-demand logic

Abstract

The present invention relates to a method for manufacturing secondary packaging according to BOD logic. This method is particularly envisaged for managing a plurality of orders, each comprising a plurality of items. For each item, a primary cuboid circumscribing it is defined, and for each order, the most compact arrangement of the items and the secondary cuboid circumscribing it are identified. Thereafter, a blank representing the flat development of the box accommodating the secondary cuboid is defined. The blank is cut from a sheet of packaging material after the arrangement has been optimized. Thus, the box is assembled from the blank and each is filled with those ordered items in the most compact arrangement. The present invention further relates to a plant applying this method.

Description

Technical Field

[0001] The present invention relates to the field of secondary packaging, and more particularly to secondary packaging made according to a logic called BOD (Box on Demand).

Background Art

[0002] In the field of product distribution, it is known to provide secondary packaging for the purpose of simplifying the handling and shipping of the products themselves.

[0003] Normally, each item is sold on the market in its own packaging called primary packaging, which is directly made by the manufacturer. Primary packaging is usually researched and manufactured for the purpose of presenting the product in the most appropriate way by the manufacturer. In fact, manufacturers often use primary packaging as a communication tool to convey the quality they want to associate with the product inside through materials, finishes, and graphics.

[0004] Conversely, secondary packaging is usually provided by entities other than the manufacturer, such as distributors, retailers, transporters, etc. Secondary packaging often contains one or more products that are unrelated to each other and each is completed with its own primary packaging. Therefore, since secondary packaging is intended to be attached to the product only at the handling and shipping stages of the product, it has a purely practical function. Secondary packaging needs to be suitable for protecting the internal product (including the primary packaging) and showing the display useful for handling and / or shipping. For this reason, secondary packaging is usually made of simple cardboard. When the product is delivered, the secondary packaging finishes its role and is discarded.

[0005] Due to the recent growth of the e-market where products are grouped, repackaged, and shipped by the seller for consumers to order products on a specific online platform, secondary packaging is becoming increasingly important.

[0006] In the field of secondary packaging, generally, on the seller's side that ships products grouped according to consumers' orders, various approaches are possible. For example, a single order may include a mobile phone with several accessories such as a backup power source, headphones, or a case, but may also include completely different items such as books and daily necessities.

[0007] The first approach is to provide the seller with the use of a predetermined box based on a finite number of dimensions and ratios. Thus, this type of approach assumes placing each product group in the smallest volume box that can accommodate the entire group. In fact, it is a general rule that the shipping cost of a package depends on its weight and volume. Once the products are determined by the order, the total weight of the package minus the weight of the secondary packaging is also determined. However, since the difference in weight between the different available boxes is considered negligible, it is preferable to minimize the volume of the package in order to minimize the shipping cost.

[0008] This method of providing secondary packaging through a predetermined box can be carried out manually or automatically. As can be well understood by those skilled in the art, when this method is applied manually, the result of the execution largely depends on the operator's experience and attention. Generally, with the manual method, it is possible to safely handle any type of product, including fragile, easily damaged, or potentially dangerous ones. On the other hand, it is shown that this takes a relatively long processing time and there is a high possibility of errors in optimizing the box volume. In fact, the operator may choose a box slightly larger than strictly necessary if it can speed up the work, especially when facing a particularly large workload. Conversely, the automatic execution of this work improves the optimization step but makes it impossible to manage fragile, easily damaged, or potentially dangerous items. To evaluate the impact of this limitation on the automatic application of the method, consider, for example, the case where all batteries commonly used in portable electronic devices are potentially dangerous due to flammability and thus cannot be managed automatically.

[0009] Since it is rare for a given box to be completely filled with a product group that makes up an order, this type of approach, which assumes the use of a finite number of types of boxes, indicates that sub-optimal solutions are used, whether manually or automatically. It is much more likely that there will be a remaining volume of empty space within each box, which needs to be filled with some kind of packing material. This represents a significant disadvantage for several reasons. First, the transportation costs associated with the volume of the box are higher than strictly necessary. Also, the systematic shipment of large boxes relative to actual need indicates an increased number of movements of cargo carriers such as aircraft, ships, or trucks. Finally, there is a consumer satisfaction issue. When receiving a partially empty box filled with packing material, consumers feel that the transportation is inefficient and has a greater environmental impact than necessary.

[0010] A different approach that attempts to address the drawbacks described above is the so-called BOD (Box on Demand), which provides for the manufacture of a specific box for each group of items or order shipped by a vendor. In other words, once the group of products to be shipped in a single order is determined, the associated box is assembled on-site by on-the-spot measurement, making the management for optimizing the volume of the box much more efficient than the method described above. More advanced BOD approaches currently require the use of very complex and expensive plants that fully automatically create and provide secondary packaging. After the operator places the ordered products, the plant detects their dimensions, cuts the box from a sheet of cardboard, and assembles the box around the products. This solution guarantees high-speed execution, but in addition to the high initial cost, like any fully automated process, it cannot handle breakable, delicate, or potentially dangerous items. Furthermore, regardless of size, this method implies a large amount of cardboard waste by using a certain amount of cardboard (e.g., a sheet) for each box. SUMMARY OF THE INVENTION

[0011] Accordingly, an object of the present invention is to at least partially overcome the above-mentioned drawbacks associated with the prior art.

[0012] In particular, the task of the present invention is to provide a method and a plant for manufacturing a secondary packaging according to the BOD logic, which are capable of handling any type of article, including fragile, vulnerable or potentially dangerous ones.

[0013] Furthermore, the task of the present invention is to provide a method and a plant for manufacturing a secondary packaging according to the BOD logic, which are particularly efficient in terms of the volume of the boxes to be manufactured and the consumption of packaging material.

[0014] Also, the task of the present invention is to provide a method and a plant for manufacturing a secondary packaging according to the BOD logic, which are very efficient in terms of cost performance ratio.

[0015] Finally, the task of the present invention is to provide a method and a plant for manufacturing a secondary packaging according to the BOD logic, which maintain the functions of the prior art as much as possible together with the incorporated advantages.

[0016] These and other objects and tasks of the present invention are achieved by the method and the plant according to the appended claims. Further features are identified in the dependent claims. All of the appended claims form an essential part of this disclosure.

[0017] According to a first aspect, the present invention relates to a method for manufacturing a secondary packaging according to the box-on-demand logic. The method of the present invention comprises providing a plurality N of orders o, each order o comprising a plurality of articles a ij ; for each article a of each order o i defining a primary cuboid circumscribing the article a ij ; ij ; for each order o iRegarding the most compact item a ij identifying the relative arrangement of for each order o i detecting the size of the secondary rectangular parallelepiped circumscribing the most compact arrangement for each order o i placing it in standby storage for each secondary rectangular parallelepiped, defining a blank representing the planar development of the box that defines an inner product equal to the secondary rectangular parallelepiped adding each blank to the standby list providing a sheet of packaging material of a predetermined size optimizing the arrangement on the sheet for at least some of the blanks in the standby list to minimize waste of the packaging material cutting the blanks on the sheet deleting the cut blanks from the standby list removing the blanks from the sheet assembling the box with the removed blanks for the order o corresponding to the assembled box i removing it from the standby list placing item a in the box according to the most compact arrangement ij and arranging it providing the box for subsequent steps repeating the steps of removing the blanks, assembling the box, removing the corresponding order, placing the item in the box, and providing the box for subsequent steps until the end of the cut blanks discarding the waste of the packaging material and repeating the method until the end of the order comprising.

[0018] The method of the present invention enables optimization of the production of secondary packaging and minimization of waste.

[0019] Preferably, for each order o i the step of identifying the most compact relative arrangement of the items a ij is performed by a recursive optimization algorithm that considers all possible relative arrangements of the items a ij , gradually modifies the positioning of each primary cuboid relative to the other primary cuboids, calculates the size of the secondary cuboid, and selects the most compact arrangement.

[0020] The optimization algorithm enables minimizing waste in the manufacture of secondary packaging by quickly and efficiently obtaining the most compact arrangement of the items.

[0021] Preferably, the recursive optimization algorithm defines each item a j by a respective primary cuboid having three measurements x j , y j , and z ij , and for each primary cuboid, identifies the measurements x j , y j , and z j starting from a point [0;0;0] called the origin located at the vertex of the cuboid, and in each primary cuboid, identifies three available vertices corresponding to the vertices located at positions [x j ;0;0], [0;y j ;0], and [0;0;z j with respect to the origin, and during the positioning step, places the origin of the new primary cuboid so as to coincide with one of the available vertices of the already positioned primary cuboid, and if the origin of the primary cuboid is located on an available vertex, discards the cuboid from the list of cuboids to be positioned so that the primary cuboid is no longer available for subsequent positioning is performed.

[0022] Preferably, the optimization algorithm further Storing the volume and size of each calculated secondary cuboid; Verifying whether the secondary cuboid corresponding to the most compact arrangement of the items has an aspect ratio between at least two sizes included in the allowable range; If affirmative, using the above secondary cuboid, or If negative, ignoring the above secondary cuboid, selecting a further cuboid related to the most compact arrangement excluding the arrangement related to the ignored secondary cuboid, and repeating the step of verifying the previous secondary cuboid; Execute.

[0023] This algorithm is particularly efficient in optimizing the arrangement of items a for each order o.

[0024] Preferably, the optimization algorithm further performs the step of adding an offset value to at least one of at least one size of the items to be arranged, and the offset value corresponds to the gap required for arranging the protective material for protecting the items while filling the package.

[0025] By adding the offset value, the protective material can be easily introduced into the package, and the safety of the package is improved.

[0026] Preferably, the method further comprises a printing step between the step of optimizing and the step of cutting the blank.

[0027] The printing step can obtain a high-quality package in terms of convenience for the operator and / or the quality perceived by the recipient.

[0028] Preferably, the method further comprises a creasing step between the step of optimizing and the step of cutting the blank.

[0029] The creasing step makes the subsequent folding step easy and accurate.

[0030] According to a second aspect, the present invention relates to a plant for manufacturing secondary packaging according to box-on-demand logic. The plant of the present invention comprises an electronic unit comprising a memory module, a refinement module, and a control module configured to provide instructions to the plant, a general-purpose storage comprising a plurality of items a, handling means configured to take out item a from the general-purpose storage and group the taken-out item a to form a plurality of orders o based on instructions provided by the electronic unit, a standby storage configured to maintain the order o in a standby state, and supply means configured to make available a sheet of packaging material of a predetermined size based on instructions provided by the electronic unit and comprising.

[0031] The electronic unit is further configured to i define a box blank for each order o, add each blank to a standby list, optimize the placement on the sheet for some of the blanks in the standby list, and delete the cut blanks from the standby list.

[0032] The plant also comprises a cutting station configured to cut from the sheet a box blank defined by the electronic unit in relation to a specific order o i based on instructions provided by the electronic unit, a pre-assembly station configured to pre-assemble the box starting from the cut blank, a packaging station, and moving means configured to make available at the packaging station the pre-assembled box together with the associated order o based on instructions provided by the electronic unit. i The plant also comprises. and also comprises.

[0033] The plant of the present invention enables the method of the present invention to be easily and accurately realized.

[0034] Preferably, the electronic unit further defines a primary rectangular parallelepiped circumscribing each item a ij and identifies the relative arrangement of the most compact item a for each order oi, detects the size of the secondary rectangular parallelepiped circumscribing the most compact arrangement, and is configured to define a blank of the associated box for each secondary rectangular parallelepiped. ij

[0035] Preferably, the plant further comprises a printing station provided between the supply means of the sheet of packaging material and the cutting station.

[0036] Preferably, the plant comprises a station for turning the sheet over.

[0037] Preferably, the plant further comprises a three-dimensional scanning device configured to detect the size of item a ij

[0038] According to some embodiments, the cutting station comprises a numerically controlled machine that performs cutting by a laser.

[0039] According to other embodiments, the cutting station comprises a numerically controlled machine that performs cutting by a blade, preferably a vibrating blade.

[0040] Preferably, the plant further comprises a robotic arm suitable for removing the blanks cut from the cutting station and supplying them to the pre-assembly station.

[0041] Preferably, the pre-assembly station comprises a workbench having a width and a length, configured to receive and support the blanks in a predetermined orientation, and two folding elements movable in the width direction w of the workbench. Extrusion means configured to extrude the blank toward the folding element and to the other side thereof in the length direction l of the workbench and comprising

[0042] Each of the folding elements comprises a helical screw surface that unfolds around a longitudinal axis b parallel to the direction l.

[0043] Further features and objects of the present invention will become more apparent from the following description.

[0044] The present invention is provided for illustrative and non-limiting purposes and will be described below with reference to several examples shown in the accompanying drawings. These drawings show different aspects and embodiments of the present invention, and reference numerals indicating structures, components, materials, and / or similar elements in different figures are, where appropriate, indicated by similar reference numerals. Further, for the sake of clarity of illustration, certain references may not be repeated in all figures.

Brief Description of the Drawings

[0045]

Figure 1

Figures 2a-2b

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

DETAILED DESCRIPTION OF THE INVENTION

[0046] The present invention is subject to various modifications and alternative structures, but specific preferred embodiments are shown in the drawings and will be described in detail below. In any case, it is not intended to limit the present invention to the specific embodiments illustrated, and on the contrary, it should be understood that the present invention is intended to include all modifications, alternatives, and equivalent structures that fall within the scope of the present invention as defined in the claims.

[0047] This specification deals in detail with specific aspects and technical features of the present invention, but aspects and technical features that are already known per se may only be suggested. In these respects, what has been described above with reference to the prior art remains valid.

[0048] The use of "for example", "such as", or "or" indicates non-exclusive alternatives without limitation, unless an exception is indicated. The use of "comprises" and "includes" means "comprises or includes, but is not limited to", unless an exception is indicated.

[0049] The method and plant of the present invention are intended to manage a plurality of orders o, each order comprising a plurality of items a. In the following description, in some cases, an index is used to indicate a specific element, and the possible first index identifies the order, and the possible second index identifies the item within the order. For example, to indicate a specific order o among a plurality of orders, the index i is used in the notation of o i is used. Similarly, for the order o iTo indicate a specific item a among a plurality of items that are part of it, an index i indicating an order and an index j indicating an item are used in the notation a ij as described.

[0050] According to a first aspect, the present invention relates to a method for manufacturing secondary packaging according to BOD logic (box on demand). The method of the present invention providing a plurality N of orders o, each comprising a plurality of items a ij (block 100); for each item a of each order o i defining a primary rectangular parallelepiped circumscribing the item a ij (block 101); ij for each order o identifying the relative arrangement of the most compact items a i (block 102); ij for each order o detecting the size of a secondary rectangular parallelepiped circumscribing the most compact arrangement i (block 103); placing each order o i in standby storage 56 (block 104); for each secondary rectangular parallelepiped, defining a blank 64 representing a planar development of a box 66 defining an inner product equal to the secondary rectangular parallelepiped i (block 105); adding each blank 64 i to a standby list (block 106); providing a sheet 60 of packaging material of a predetermined size (block 107); optimizing the placement on the sheet 60 for at least some of the blanks 64 in the standby list to minimize waste of the packaging material (block 108); cutting the blanks 64 of the sheet 60 (block 109); deleting the cut blanks 64 from the standby list (block 110); the blank 64i The step of taking out i from the sheet 60 (block 111), and the blank 64 taken out i is used to assemble the box 66 i The step of assembling (block 112), and the assembled box 66 i The corresponding order o i The step of taking out from the standby storage 56 (block 113), and According to the most compact arrangement, the box 66 i The step of arranging items inside (block 114), and For subsequent steps, the box 66 i The step of providing (block 115), and The step of taking out the blank 64, the step of assembling the box 66, the step of taking out the corresponding order, the step of arranging items inside the box 66, and the step of providing the box 66 for subsequent steps are repeated until the end of the cut blank 64 (block 116), and The step of discarding waste packaging materials (block 117), and The step of repeating the method until the end of the order (block 118) and Comprising.

[0051] As will be readily understood by those skilled in the art, the method of the present invention is intended to be used in a situation where a plurality of N orders o arrive almost continuously from the upstream general storage 54. Preferably, each order o i Is, in part, the item a i All of which are configured in the upstream storage by being placed step by step in a single container 72. Such a container 72 is uniquely identified in a known manner by a technology based on automatic recognition, for example, an optical code (for example, a barcode, a QR code (registered trademark), etc.), or a short-range signal (for example, RFID, NFC, etc.). In this way, the plant 50 can always track a single order o i In each container 72i.

[0052] Each item a ij The step (block 101) of defining the primary rectangular parallelepiped circumscribing the item, i.e., the rectangular parallelepiped with the minimum volume that completely houses the item a ij can be performed in various ways. In some cases, the item a ij actually has a rectangular parallelepiped shape, but in other cases, the item a ij can have a different shape. In any case, any shape can be inscribed in a primary rectangular parallelepiped having walls that contact the actual shape. This primary rectangular parallelepiped is considered in subsequent steps of the method. In the following description, each individual item is represented by itself as a primary rectangular parallelepiped, which is why they can be referred to indifferently using the same reference sign a ij for the reason that they can be referred to them indifferently even using the same reference sign a

[0053] In some cases, the size of the item a ij is already known, for example because it is available from the manufacturer or because the same item has been processed in the same way in the past. However, if the size of the item a ij is not available, they can be detected on-site, for example by using a 3D scan. Preferably, this scan is performed simultaneously while an item a ij of unknown size slides on a conveyor belt

[0054] Also, the step (block 102) of identifying the relative arrangement of the most compact items a i for each order can also be performed in various ways. In principle, the operator can attempt to position the items of the order relative to each other to obtain the most compact arrangement. However, according to a preferred embodiment, the steps of this method are automatically performed to perform it more quickly and improve the optimization of the result. For this purpose, for example, a commercially available 3D optimization algorithm (hereinafter also referred to as a 3D algorithm) can be used. A recursive 3D algorithm of the type described later is particularly advantageous for the purposes of the present invention

[0055] The 3D algorithm for each individual order o in items a i1 a i2 ···a in operates on. The 3D algorithm receives, as input, the sizes of the individual cuboids defined in the previous step, and encloses all the (order o i of items a ij represented) cuboids in the most compact arrangement possible, and supplies, as output, the size of the cuboid (desired box 66 i represented) that encloses them.

[0056] The 3D algorithm considers all possible relative arrangements of the items, gradually modifies the position of each cuboid relative to the other cuboids, calculates the sizes of all the cuboids, and selects the most compact arrangement. In one embodiment, such a 3D algorithm 1020 comprises the following steps described with respect to the flowchart of FIG. 2.

[0057] For each item a i of the same order o ij the corresponding cuboid calculated in step 101 is obtained (step 1021).

[0058] In the example considered, each cuboid is defined by three measurements x j (width), y j (depth), and z j (height). The measurements x j , y j , and z j begin at a point [0;0;0] called the origin corresponding to the first vertex of the cuboid.

[0059] The largest of the three sizes defining each cuboid is always selected as the measurement of the width x j , and the smallest of the three sizes defining each cuboid is always selected as the measurement of the height z j .

[0060] The origin of item a ij is the three elements x j , yj , z j (width, depth, height) are defined so as to be the three right - hand elements.

[0061] Also, for each primary cuboid, three available or free vertices are identified, which are the vertices at positions [x j ; 0; 0], [0; y j ; 0], and [0; 0; z j with respect to the origin.

[0062] The 3D algorithm 1020 is assumed to select the first primary cuboid with a larger surface size among the cuboids related to the item a ij of the same order o (step 1023). Specifically, the product of the width x j and the depth y j is larger than the same product of the remaining primary cuboids related to the item a i of the same order o ij . Then the primary cuboid is selected.

[0063] The example in Figure 3 schematically shows four primary cuboids representing four items a i that make up a single order o i1 , a i2 , a i3 , and a i4 . For the sake of simplicity, in Figure 3, the origin and the available vertices are explicitly shown only for the item a i1 . The 3D algorithm starts by first considering the largest cuboid among those included in the order. For the purpose of this explanation, the first primary cuboid is the one related to the item a i1 .

[0064] Once the largest primary cuboid is identified, the algorithm generates all possible orderings of the items in the order while holding the one corresponding to the largest cuboid as the first item.

[0065] For example, referring to Figure 3 again, when the one related to the item a i1 is identified as the largest cuboid, the algorithm 1020 takes ai1 While retaining i1 as the first element, all possible arrangements of four items, [a i1 ; a i2 ; a i3 ; a i4 , [a i1 ; a i2 ; a i4 ; a i3 , [a i1 ; a i3 ; a i4 ; a i2 , [a i1 ; a i3 ; a i2 ; a i4 , [a i1 ; a i4 ; a i2 ; a i3 and [a i1 ; a i4 ; a i3 ; a i2 are generated.

[0066] The origin [0; 0; 0]1 of the selected first rectangular parallelepiped corresponding to the origin of the determined second rectangular parallelepiped is set (step 1025). This step substantially corresponds to the positioning of the first rectangular parallelepiped within the second rectangular parallelepiped.

[0067] Thereafter, the next rectangular parallelepiped associated with one of the remaining items a i of the same order o ij is selected (step 1027). Preferably, excluding the first rectangular parallelepiped, the next rectangular parallelepiped having the largest surface among the rectangular parallelepipeds associated with the items a i of the same order o ij is selected. In the example of FIG. 3, the next rectangular parallelepiped associated with the item a i2 is selected.

[0068] The 3D algorithm 1020 is assumed to calculate the n possible positions of the next rectangular parallelepiped such that the origin [0; 0; 0]2 of the next rectangular parallelepiped coincides with one of the available vertices [x j ; 0; 0], [0; y j ; 0], and [0; 0; z j of the initial rectangular parallelepiped (step 1029).

[0069] In an alternative embodiment, an offset value, i.e., the gap remaining between various items within the box, is defined. For example, the offset value may be added to one or more of each size of item a of the same order o i of item a ij These gaps are then filled with a filling and protective material during the step of packaging the items.

[0070] Additionally or alternatively, the calculated positioning is a subset of the n possible positionings. In particular, one or more of item a ij can be associated with a prohibited positioning or a permitted positioning. In this way, it is possible to prevent item a ij from being placed within the box in a manner that would damage or harm item a ij .

[0071] Next, for each of the n positionings, a partial confinement volume is calculated (step 1031). Each partial confinement volume corresponds to the volume of a parallelepiped comprising an initial primary rectangular prism and a next primary rectangular prism arranged according to the corresponding nth positioning.

[0072] The 3D algorithm 1020 then processes item a of the same order o ijSteps 1027 to 1031 are repeated until the primary cuboids related to it are considered (decision step 1033). In other words, algorithm 1020 considers all possible arrangements, starting from the cuboid with the largest size, and recursively considers all possible mutual positioning permutations of the primary cuboids. In fact, when the largest cuboid is positioned, the second cuboid is positioned by placing its origin at each of the three available vertices of the largest cuboid. For each of the available vertices, the second cuboid is rotated to all possible positions, and one face of the second cuboid is superimposed on one face of the first cuboid. Thus, each of the generated arrangements has the available vertices of both cuboids, except for the vertex of the first cuboid where the origin of the second cuboid is placed. For each of these arrangements, the third cuboid is then positioned by placing its origin at each of the available vertices of the already positioned primary cuboids and by rotating it to all possible positions. In this way, the process is repeated until all mutual arrangements of the primary cuboids are obtained.

[0073] Preferably, the combination of cuboids is executed in ascending order of the partial confinement volume. In other words, after the third primary cuboid to be positioned, the combination of cuboids is calculated starting from the arrangement of the previous primary cuboid having the smallest partial confinement volume among the possible arrangements of the already considered primary cuboids. In some embodiments, it is envisaged to define an exception to this rule, for example, positioning article a ij as the last one, or imposing that a number of articles greater than a threshold number do not lie on top. This can prevent structurally delicate articles from being damaged or impaired by the weight of other articles.

[0074] For each of the obtained arrangements, when all possible arrangements comprising all the primary cuboids of order o i are generated (output branch Y of decision step 1033), the 3D algorithm has the measurement values X i , Y i and Z iand the volume X of the secondary rectangular parallelepiped circumscribing the arrangement i * Y i * Z i are calculated and stored (step 1035). All data regarding each arrangement and the associated secondary rectangular parallelepipeds are stored in a temporary list sorted in ascending order of volume from the secondary rectangular parallelepiped with the smallest volume to the one with the largest volume.

[0075] Preferably, the temporary list contains a limited number of arrangements starting from the one with the smallest volume. In practice, the number of possible conditions increases rapidly as the number of items a i in order o ij increases, and maintaining the complete list is computationally extremely burdensome and may be unnecessary from a practical point of view. For example, the temporary list may be limited to a maximum of 100 arrangements. If order o i provides a larger number of possible arrangements, only the data of the 100 with the smallest volume among them are stored.

[0076] In one embodiment, a secondary offset value corresponding to the gap remaining between the secondary rectangular parallelepiped and the box wall can be defined so that the filling and protective materials can be inserted during the packaging procedure in a similar manner as described above.

[0077] Figures 4 and 5 each represent two different arrangements of the items in Figure 3. As can be seen at an intuitive level, the arrangement in Figure 4 is more compact than the arrangement in Figure 5.

[0078] According to some embodiments, the 3D algorithm 1020 selects the most compact arrangement among those calculated when generating the secondary rectangular parallelepiped with the smallest volume, that is, the first one in the temporary list (step 1037). In this case, the first secondary rectangular parallelepiped in the list is considered appropriate and the subsequent steps of method 100 are initiated (step 1039), and in particular, for this rectangular parallelepiped, the blank 64 i for manufacturing the box 66 i intended to accommodate order oi is initially defined.

[0079] Alternatively, the 3D algorithm 1020 can be configured to use different placement selection criteria. For example, in an alternative embodiment, the 3D algorithm 1020 is configured to select a placement associated with a rectangular cuboid having the smallest total surface area among the calculated rectangular cuboids in order to minimize the consumption of packaging material.

[0080] Preferably, the 3D algorithm 1020 is for the rectangular cuboid and the associated blank 64 i measurement value X i Y i and Z i can perform several checks. In particular, the checks can be aimed at verifying whether the measurement values X i Y i and Z i are included within a dimensional range that can be properly managed by the plant 50. In fact, each of the stations of the plant 50 (such as the cutting station 62 or the pre-assembly station 68 described later) can manage only blanks 64 that are included within a specific dimensional range.

[0081] The 3D algorithm 1020, when it verifies that the blank 64 i has one or more sizes below a minimum, may intervene in various ways depending on the embodiment of the present invention. For example, the 3D algorithm 1020 may forcibly increase an unduly small size until it reaches the respective minimum value so that the blank 64 can be managed. Optionally, in this case, the 3D algorithm 1020 can also notify the opportunity to introduce filling and protective materials to fill the empty spaces within the forcibly enlarged box. Alternatively, the 3D algorithm 1020 interrupts the manufacturing procedure of the blank 64 and places an order o i i i ​​can be converted to another line that can be managed in a different way, such as manually. Finally, as an alternative or addition, the 3D algorithm 1020 may inform the operator of the problem.

[0082] Regarding the maximum dimension range, it is preferred that an empirical preliminary check is performed on all items managed by storage. If a single item exceeds the maximum size that can be managed by the plant, it is clear that this item needs to be managed in a special way. What is different here is the blank 64 that is the subject of the check performed by the 3D algorithm 1020 i whose excessive size is i derived from the arrangement of a number of items a ij that make up the order o i In this case, the 3D algorithm 1020 verifies that the blank 64 i has one or more sizes that exceed the maximum range, and then, depending on the embodiment of the present invention, may intervene in various ways. For example, the 3D algorithm 1020 may force the order o i to be separated into two sub-orders that can each be accurately managed as a single order. Alternatively, the 3D algorithm 1020 may interrupt the manufacturing procedure of the blank 64 i and convert the order o

[0083] According to other embodiments, the 3D algorithm 1020 measures the dimensions X i Y i and Z iPerform a further check on the ratio between (indicated by the dashed line step between step 1037 and step 1039). The purpose of this check is to prevent boxes 66 with extreme ratios between the measured values from being assembled. In fact, since these boxes 66 can be fragile, in subsequent steps of this method (typically handling and shipping), there is a risk that each item will be exposed to the possibility of damage.

[0084] To avoid such a situation, a limit ratio P is defined, and the 3D algorithm 1020 verifies whether the first cuboid in the temporary list (i.e., the one with the smallest volume) satisfies the condition (1 / P) < R < P (decision step 1041), where R is sometimes the ratio between two of the three measurements of the cuboid, i.e., R will then take on the values X i / Y i 、Y i / Z i 、and X i / Z i is assumed.

[0085] If the first cuboid in the list satisfies the condition for the limit ratio P (output branch Y of decision step 1041), that cuboid is considered appropriate and taken into account in subsequent steps of the method, i.e., the method proceeds to step 1039. Otherwise (output branch N of decision step 1041), the first cuboid is considered inappropriate, and the 3D algorithm selects the second cuboid in the temporary list, i.e., the one with the next smallest volume (step 1043) and returns to verification step 1041. In other words, in this case, the 3D algorithm 1020 proceeds iteratively until it finds an appropriate cuboid, i.e., the one with the smallest volume among those that satisfy the condition for the limit ratio. As an example, the limit ratio P can be set equal to 20.

[0086] In an alternative embodiment, if it is not possible to identify a rectangular cuboid that satisfies the condition for the limit ratio P, the 3D algorithm is assumed to repeatedly iterate steps 1041-1043 by decreasing the value of the limit ratio P until an appropriate rectangular cuboid is identified. As an example, the value of the limit ratio P can be decreased by 10% in each trial.

[0087] Once an appropriate rectangular cuboid is identified, for subsequent steps of placing item a i inside box 66 ij the relevant placement is stored in combination with order o i At this point, to lighten the system memory, it is possible to discard a temporary list that is no longer used and that has all non-compact placements and the associated inappropriate rectangular cuboids.

[0088] When order o i is considered, i.e., when the most compact placement of the relevant item a ij is identified and stored, order o i is placed in standby storage 56 within container 72 i Standby storage 56 is non-continuous automated access storage and container 72 can be accessed in any order in an automated manner.

[0089] Next, the method provides for defining a blank 64 that represents a planar development of box 66 that respectively defines an inner product equal to each of the appropriate rectangular cuboids identified in the previous step.

[0090] Preferably, the blank 64 is defined based on the well-known RSC standard (container with standard slots) shown as an example in FIG. 6. In the box 66 obtained from the blank 64RSC, side walls are obtained by subsequent folds of a single continuous element, and at one end thereof, fins (or "manufacturer's edges") for adhering to the opposing ends are provided. The upper and lower ends of the box 66 are obtained by closing flaps that form extensions of the side walls. All closing flaps have the same length from the fold to the edge. Thus, the closing flaps extending from the long sides touch at the center, but the closing flaps extending from the short sides do not touch (see, for example, FIG. 7).

[0091] Once defined, the blank 64 i is added to the standby list. Thus, this method assumes maintaining a one-to-one relationship between the order o and the blank 64 by having multiple orders in each container 72 in the standby storage 56 and having the corresponding blank 64 in the standby list.

[0092] Next, this method assumes providing a sheet 60 of packaging material of a predetermined size. The packaging material is preferably easy to cut and fold to facilitate the manufacture of secondary packaging, semi-rigid so as to be able to protect the contents, and economical. For these reasons, the packaging material is preferably cardboard of the type commonly used for manufacturing conventional secondary packaging. Although other packaging materials may be used in the method of the present invention, for the sake of brevity of presentation, cardboard, particularly raw cardboard, is hereinafter referred to.

[0093] This type of cardboard can be made available in various shapes. One possible shape is a continuous roll shape from which the cardboard is gradually unwound. In this case, the cardboard sheet 60 has a fixed size (referred to as the width), but the other size (length) is indeterminate beforehand. For the purposes of this method, it is also preferable to establish the maximum length of the sheet 60, for example based on the size of the cutting station 62. In this way, the size of the sheet 60 is predefined.

[0094] According to other embodiments, the cardboard is provided in the form of a continuous paper composed of a single structurally continuous element folded in an accordion shape or in a Z shape, also called a continuous form. Also in this case, the sheet 60 has a fixed width, but the distance between two subsequent predetermined fold lines is preferably considered as a length. Thus, in the most widespread method for managing continuous paper cardboard, the size of the sheet 60 is predefined.

[0095] However, if there are specific needs, it is possible to consider sheets of longer or shorter lengths. As is well understood by those skilled in the art, the choice of adopting sheets of lengths different from the distance between the predetermined fold lines generally has the effect of obtaining one or more blanks where the predetermined fold lines intersect. As described above, the cardboard is structurally continuous, and the relative weakness constituted by the predetermined fold lines is usually compensated by the shape resistance of the box 66 when properly assembled, so this event does not involve major drawbacks. Therefore, with respect to the cardboard sheet 60, a length different from the distance between the predetermined fold lines may be established (for example, based on the size of the cutting station 62), but in any case, the size of the sheet 60 is predefined.

[0096] According to other embodiments, the cardboard is provided as a stack of single pre-cut sheets 60. In this case, the size of the sheet 60 is predefined.

[0097] Regardless of how the packaging material is supplied (roll, continuous paper, or single sheet), in some cases, the considered width available for positioning the blank 64 is preferably slightly smaller than the actual width. When the steps of managing and cutting the blank 64 (blocks 107 and 109) are performed in an automated manner, it is preferable to avoid damaging the two strips 74 at both ends of the sheet 60 and thus keep them unavailable for cutting. Therefore, the supply means 58, such as a wheel suitable for advancing the sheet 60 by friction, can usually act on such strips 74 and supply the packaging material to the cutting station 62.

[0098] When a specific quantity of blanks 64 is accumulated in the standby list, the method assumes optimizing the arrangement of the blanks 64 within the sheet 60. To perform this step efficiently, a two-dimensional optimization algorithm called nesting is available in this field and enables a very high level of optimization. Hereinafter, the two-dimensional optimization algorithm is simply called the 2D algorithm.

[0099] Therefore, the 2D algorithm minimizes defective products and material waste by selecting a subset of blanks 64 that optimally fills the sheet 60 from among the multiple blanks 64 in the standby list. Subsequently, the subset of blanks 64 is traced onto the sheet 60 for subsequent cutting steps and removed from the standby list.

[0100] Preferably, the result of the 2D algorithm is a map of the arrangement of the blanks 60 on the sheet 60 (see FIG. 8).

[0101] As will be readily understood by those skilled in the art, the pure optimization criterion of the 2D algorithm does not guarantee restrictions on the permanence of a specific blank 64 within the standby list. In other words, although statistically unlikely, a specific blank 64 i is not guaranteed. imay not be removed from the list and may remain for an infinite time. Associated order o i To avoid this kind of event that may leave bad results in i , specific constraints may be introduced into the 2D algorithm. In other words, it is possible to force the 2D algorithm to introduce into the subset the delayed blank 64, that is, the blank 64 remaining in the standby list for a time longer than a predetermined limit. Therefore, the 2D algorithm starts by positioning the delayed blank 64 and then freely positions the other blanks 64 selected from the standby list only for the purpose of maximizing the configuration of the sheet 60. This management method of the delayed blank 64 may sometimes result in suboptimal solutions, but guarantees that all orders are processed within the maximum time determined by the administrator.

[0102] FIG. 8 schematically shows a map generated by the 2D algorithm, that is, a sheet 60 in which four RSC64 blanks are arranged to minimize waste of materials. However, the sheet 60 of FIG. 8 is provided with end strips 74 for automatic movement.

[0103] Preferably, the printing step may be sandwiched between the 2D optimization step (block 108) and the step of cutting the blank 64 (block 109). The printing step may be performed by a technique commonly used in the field of packaging, preferably a digital printing technique that enables a printing area to be defined for each blank 64 based on a map generated by the 2D algorithm. For example, the printing step may be performed by an inkjet printer, preferably a thermal inkjet.

[0104] Printing may vary for each blank 64 i for example, for the blank 64 i with the defined order o iA unique identifier (e.g., an alphanumeric string, barcode, QR code (registered trademark), etc.), information useful for shipping such as the name and address of the recipient, a logo or brand identifying the vendor or service administrator, an advertising message, a message personalized for the recipient, etc., may reproduce information useful for subsequent steps.

[0105] Printing may cover both sides of sheet 60, and some information is preferably intended to appear outside box 66 obtained from blank 64 (e.g., the shipping address), and other information is preferably intended to appear inside box 66 (e.g., a private message to the recipient).

[0106] Preferably, after the printing step, there is a step of turning over sheet 60. Subsequent to the step of turning over sheet 60, there may be a second printing step and / or a step of cutting blank 64 (block 109). As will be readily understood by those skilled in the art, turning over sheet 60 necessarily requires turning over a map generated by a 2D algorithm, based on which the cutting step is performed.

[0107] The method of the present invention may advantageously comprise a step of making a crease, i.e., a step provided with a folding lead-in (referred to as crease 88) facilitating the subsequent folding operation of blank 64. Preferably, such a creasing step is performed when sheet 60 is still intact, between the 2D optimization step (block 108) and the step of cutting blank 64 (block 109). Depending on specific requirements, the creasing step may be performed before or after the printing step and / or before or after the step of turning over sheet 60.

[0108] Along the crease 88, the material of the sheet 60 is compressed to locally reduce the moment of inertia of the cross-section, thereby defining a preferential folding line. For example, if the sheet 60 is made of cardboard, along the crease 88, the two outer sheets are brought closer to each other by flattening the waves of the intermediate sheet.

[0109] The creasing step can be performed by a compressing element that obtains the crease 88 by following the folding line defined by a 2D algorithm. For example, the creasing step can be performed using a Cartesian plotter that uses a pressure wheel as an end effector.

[0110] In FIGS. 6 and 8, the dashed lines included within the blank 64 schematically represent the crease 88. In each blank 64, a total of six creases 88 are provided according to the RSC type. Two creases 88 (generally long, parallel to each other, and horizontal in FIG. 6) define the folding line between the side wall of the box 66 and the closing flap, and the other four creases 88 (generally short, perpendicular to the first two, and vertical in FIG. 6) define the folding lines between adjacent side walls and between the end side wall and the small adhesive fins.

[0111] The step of cutting the blank 64 of the sheet 60 (block 109) can be performed in various ways, preferably by using a numerically controlled machine. According to some embodiments, the cutting can be performed by a blade or a numerically controlled milling machine. Preferably, the cutting is performed by a Cartesian plotter that uses a blade, such as a vibrating blade, as an end effector. Such a solution is preferred in some embodiments because it is simple and relatively low-cost. According to other embodiments, the cutting can be performed by a numerically controlled laser that is either a Cartesian laser or a scanning laser. The use of a laser is preferred in some embodiments because of its high reliability and reduced maintenance requirements.

[0112] Preferably, by employing two different end effectors, namely a creasing wheel and a cutting blade, the same Cartesian plotter can perform the creasing step and the cutting step.

[0113] Also, by means of a laser, it is possible to proceed with marking the blank 64, for example, with information useful for subsequent steps, by adopting low power to facilitate creases, crease leads-ins for subsequent folding operations, and pre-cut lines that will later enable the box 66 to be unpacked along a predetermined line, and / or. For example, by means of a laser, the blank 64 i can be marked with the unique identifier of each order o i in the form of, for example, an alphanumeric string, barcode, QR code (registered trademark), etc., information useful for shipping such as the name and address of the recipient, a brand identifying the seller or service administrator, etc.

[0114] If the laser needs to act on both sides of the blank 64, it is possible to provide a station configured to turn the blank 64 over, or to arrange two different laser devices provided on two opposite sides of the blank 64.

[0115] Once the blanks 64 are cut, the method assumes taking them out one by one and assembling the associated boxes 66 for each of them. The step of taking out one blank 64 i (block 111) is preferably carried out automatically, for example, by a robotic arm. A SCARA (Selective Compliance Assembly Robot Arm) robot equipped with one or more suction cups as an end effector is particularly suitable for this type of operation. Other robots suitable for performing the step of taking out each blank 64 i (block 111) are, for example, articulated robotic arms or Cartesian portal robots. Once taken out from the cutting station 62, the cut blank 64i is supplied to the pre-assembly station 68 of the box 66 i .

[0116] The step of assembling the box 66 starting from the cut blank 64 (block 112) can also be performed in various ways. For example, it may be suitable to automatically perform a pre-assembly step and then manually complete the assembly.

[0117] In a preferred example where the blank 64 is of the RSC type, the step of pre-assembling the box 66 is assumed to first fold the side walls with fins inward and then fold the opposing side walls inward to cover the fins. Thereafter, it is necessary to provide joining means in a manner known per se to join the fins to the opposing side walls. For example, the joining means may be an adhesive, double-sided tape, metal staples, etc.

[0118] This pre-assembly step of the box 66 can be automatically performed by a special station that performs folding operations and joining operations (such as by adhesion). Preferably, this step is performed using an automatic pre-assembly station for the box 66 of the type described in a patent document titled PRE-ASSEMBLY STATION FOR PACKAGINGS OF VARIABLE SIZES, developed by the same owner and filed on the same date.

[0119] The automatic pre-assembly station 68 is configured to receive, as input, a blank 64 representing a flat development of at least two boxes 66 of different sizes and to discharge, as output, the pre-assembled boxes. The pre-assembly station 68 comprises a workbench having a width and a length, configured to receive and support the blank 64 in a predetermined orientation, two folding elements 80 movable in the width direction w of the workbench, and extrusion means 86 configured to extrude the shape 64 towards the folding elements 80 and outwards in the length direction l of the workbench. and

[0120] Furthermore, each of the folding elements 80 comprises a helical screw surface that unfolds around a longitudinal axis b parallel to the direction l.

[0121] The automatic pre-assembly station 68 described above provides a step of representing a planar unfolding of the box 66 and providing a blank 64 with two folding axes f; a step of placing the blank 64 on the workbench of the pre-assembly station 68 in a predetermined orientation; a step of aligning the folding elements 80 of the pre-assembly station 68 with the folding axes f of the blank 64; a step of pushing the blank 64 toward the folding elements 80 and out beyond them to enable pre-assembly of the variable-sized box 66.

[0122] When the two side walls are joined, a pre-assembled box 66 is obtained. In this state, the box 66 has a structural continuity of the side walls, but since it folds under its own weight, it needs to be closed at the upper and lower ends. Therefore, in order to complete the assembly of the box 66, it is necessary to space the side walls apart from each other so that two side walls are vertical, and it is again necessary to fold the closing flaps intended to form the bottom surface of the box 66. Also in this case, it is necessary to provide joining means, in a manner known per se, such as adhesives, adhesive tapes, double-sided tapes, metal staples, etc.

[0123] According to the method of the present invention, this second part of the assembly of the box 66 is preferably carried out manually by one or more operators. Even more preferably, together with a single pre-assembled box 66 i the operator also receives a container 72 that is taken out of the standby storage 56 and contains the order o i corresponding to that particular box 66 i . Preferably, the same operator places the items a i of the order o i in the box 66 ij in the most compact arrangement.i It also receives instructions on how to arrange them inside.

[0124] By manually performing these operations, the plant 50 can be significantly simplified, thus reducing the initial investment cost. Moreover, it is possible to handle all types of items, including those that are fragile, easily damaged, or potentially dangerous. Therefore, the method is very robust and uniform and does not require diverse handling.

[0125] Box 66 i Once the assembly of is completed, the operator can proceed to place the item a of order o according to the most compact arrangement. i of item a ij For this purpose, the packaging station 70 is preferably suitable for providing the operator with instructions that enable the operator to faithfully reproduce the most compact arrangement previously identified through a 3D algorithm. For example, various item a (identified based on appearance, special numbering, etc.) can be virtually positioned within the volume defined by the box 66 in the correct order and correct orientation, and a dynamic pattern or short video can be generated and shown on the monitor 78. ij are i positioned within the volume defined by the box 66 in the correct order and correct orientation, and a dynamic pattern or short video can be generated and shown on the monitor 78.

[0126] At this point, for subsequent steps beyond the method of the present invention, such as attaching shipping documents, closing, pasting instructions such as warnings regarding handling, and the recipient's address, it is possible to provide the box 66. i

[0127] ​Steps of the method (blocks 111 - 115) that follow the step of cutting the blank 64 of the sheet 60, i.e., briefly, the step of taking out the cut blank 64 (block 111), the step of assembling the associated box 66 (block 112), the step of taking out the corresponding order from the standby storage 56 (block 113), the step of arranging the items in the box 66 according to the most compact arrangement (block 114), and the step of providing the box 66 for subsequent steps (block 115) need to be repeated until the end of the cut blank 64 of the sheet 60. When the cut blank 64 ends, the waste of the packaging material is discarded and a new sheet 60 (block 107) can be provided.

[0128] In between, this time the previous steps of the method (blocks 101 - 106) are repeated as described above, new blanks 64 are defined, stored in the standby list, and each order is placed within the standby storage 56.

[0129] After that, the method may proceed to a new step of two - dimensional optimization of other blanks 64 of the new sheet 60 and subsequent steps.

[0130] Finally, the method of the present invention can be repeated until the end of the order (block 118).

[0131] According to a second aspect, the present invention relates to a plant 50 for manufacturing secondary packaging according to BOD logic (Box on Demand). The plant 50 of the present invention comprises an electronic unit 52 comprising a memory module, a refinement module, and a control module configured to provide instructions to the plant 50, a general - purpose storage 54 comprising a plurality of items, based on the instructions provided by the electronic unit 52, taking out items from the general - purpose storage 54, grouping the items taken out to constitute a plurality of orders Handling means configured as such, Standby storage 56 configured to maintain an order in a standby state, Supply means 58 configured to make available a sheet 60 of packaging material of a predetermined size based on an instruction provided by the electronic unit 52, Cutting station 62 configured to cut a blank 64 of a box 66 defined by the electronic unit 52 from the sheet 60 based on an instruction provided by the electronic unit 52 in relation to a specific order, Pre - assembly station 68 configured to pre - assemble the box 66 starting from the cut blank 64, Packaging station 70, Moving means configured to make the pre - assembled box 66 available at the packaging station 70 together with the related order are provided.

[0132] Also, the electronic unit 52 is configured to define a blank 64 of the box 66 for each order o i add each blank 64 to a standby list, optimize the placement on the sheet 60 for at least some of the blanks 64 in the standby list, and delete the cut blank 64 from the standby list as such. is configured.

[0133] As can be well understood by those skilled in the art, the following description of the plant 50 refers, explicitly or implicitly, to the description of the method described above. The plant 50 described hereinafter is actually configured to execute the steps of the method of the present invention.

[0134] The general-purpose storage 54 and handling means, as well as the standby storage 56 and transfer means, are not described in detail since they are themselves widely known in the logistics field. In particular, these are known in the field of automated storage and archive management. As will be readily understood by those skilled in the art, both storages 54, 56 have discontinuous access and objects can be stored and retrieved in an automated manner and in any order.

[0135] The general-purpose storage 54 is basically a large automated supermarket configured to potentially store all items provided for sale by the administrator, usually with multiple typical examples for each item. On the other hand, the standby storage 56 is smaller and is preferably configured to temporarily store assembled orders, each in its respective container 72.

[0136] Both storages 54, 56 and the handling means and transfer means operate based on the sharing of unique identification of objects, positions, and containers 72. Such unique identification utilizes technologies based on automatic recognition by, for example, optical codes (such as barcodes, QR codes (registered trademarks), etc.) or short-range signals (such as RFID, NFC, etc.).

[0137] The electronic unit 52 performs all processing steps (blocks 101, 102, 103, 105, 106, 108, and 110), that is, for each item a ij defining the primary rectangular parallelepiped circumscribing it, and for each order o i finding the most compact item a ijidentifying the relative arrangement thereof, detecting the size of the secondary cuboid circumscribing the most compact arrangement, defining the blank of the associated box for each secondary cuboid, adding each blank to the standby list, optimizing the arrangement on sheet 60 regarding some of the blanks in the standby list, and deleting the blanks cut from the standby list. The electronic unit 52 is further configured to store all the necessary information in an orderly manner and provide instructions for controlling the plant 50 in carrying out the method based on such processing and information.

[0138] Preferably, in addition to being temporarily stored for carrying out the method of the present invention, the information acquired by the electronic unit 52 may be stored in a database for later reference by the plant administrator or manufacturer, or for sale to a third party if stipulated in a commercial agreement.

[0139] In particular, the electronic unit 52 is configured to define a primary cuboid circumscribing each item a ij (block 101). Specifically, if the sizes of the items are known, the electronic unit 52 acquires them from the relevant database, whether remote or local, and is configured to store them in combination with a specific item a ij .

[0140] Otherwise, if the sizes are not available, the electronic unit 52 is configured to detect such sizes by 3D scanning. To be optimally managed in the case of items with unknown sizes, the plant 50 preferably comprises a 3D scanning device (not shown) which is itself known. Preferably, such a 3D scanning device is configured to operate continuously, for example while an item a ij of unknown size is being moved by handling means, for example while sliding on a conveyor belt.

[0141] Thereafter, the electronic unit 52 processes each order o iRegarding the most compact item a ij is configured to identify the relative arrangement (block 102). For this purpose, the electronic unit 52 is preferably configured to employ the three-dimensional optimization algorithm (or 3D algorithm) described above with respect to the method.

[0142] The electronic unit 52 is configured to detect the size of the circumscribed secondary cuboid of the identified most compact arrangement (block 103) and to define a blank 64 representing the planar development of the box 66 that defines an inner product equal to the secondary cuboid (block 105). The electronic unit 52 is further configured to store such information in combination with a specific order o i In particular, the electronic unit 52 manages the standby list of the blank 64 for the orders placed in the standby storage 56 (block 106).

[0143] The electronic unit 52 is configured to optimize the arrangement on the sheet 60 of a predetermined size with respect to at least some of the blanks 64 in the standby list in order to minimize the waste of packaging material (block 108). For this purpose, the electronic unit 52 is preferably configured to employ a known type of two-dimensional optimization algorithm (2D algorithm).

[0144] When the sheet-like arrangement with respect to some of the blanks 64 is optimized, the electronic unit 52 is configured to provide commands to the supply means 58 and the cutting station 62.

[0145] The supply means 58 comprises provisions for packaging material which can take the form of a roll, continuous paper, or a single sheet, typically cardboard. Further, the supply means 58 is configured to supply a single sheet 60 of a predetermined measurement to the cutting station 62 based on an instruction provided by the electronic unit 52. Preferably, the supply means 58 comprises wheels suitable for moving the sheet 60, which act by friction on two strips 74 provided at the ends of the sheet 60 itself for this purpose. The cutting station 62 preferably comprises a numerically controlled machine. According to some embodiments, the cutting station 62 comprises a numerically controlled machine that mechanically performs the cutting, for example, by means of a blade or a milling machine. The cutting station 62 may comprise, for example, a Cartesian plotter using a blade, preferably a vibrating blade, as an end effector. According to other embodiments, the cutting station 62 comprises a numerically controlled machine that performs the cutting by means of a laser, for example, a Cartesian laser or a scanning laser.

[0146] Preferably, the plant 50 further comprises a printing station (not shown) provided upstream of the cutting station 62.

[0147] The printing station may operate according to techniques commonly used in the field of packaging, preferably digital printing techniques that allow a printing area to be defined for each blank 64 each time based on a map generated by a 2D algorithm. For example, the printing station may comprise an inkjet printer, preferably a thermal inkjet.

[0148] According to some embodiments, the printing station may operate on both sides of the sheet 60. In fact, as already mentioned, some information is preferably intended to appear on the outside of the box 66, and other information is preferably intended to appear on the inside of the box 66.

[0149] Preferably, the plant 50 further comprises a turning station (not shown) configured to turn the sheet 60, provided upstream of the cutting station 62.

[0150] The turning station is configured to turn the sheet 60 after the first printing step. Further, the turning station is configured to make the sheet 60 reusable for the printing station (when the second printing step is performed on the opposite side) and / or make the sheet 60 available for the cutting station 62.

[0151] Preferably, the plant 50 further comprises a creasing station (not shown), advantageously provided simultaneously with or upstream of the cutting station 62. The creasing station is configured to move a pressing element over the sheet 60 in order to compress the material of the sheet 60 along a crease line defined in a map generated by a 2D algorithm. By pressing the pressing element against the crease line, a crease 88 is generated.

[0152] The creasing station may comprise, for example, a Cartesian plotter using a pressing wheel as an end effector.

[0153] Preferably, by simply employing two different end effectors, a creasing wheel and a cutting blade, the same Cartesian plotter can represent both the creasing station and the cutting station 62.

[0154] Preferably, the plant 50 comprises a robotic arm 76 suitable for removing the blanks 64 cut from the cutting station 62 and supplying them to the pre-assembly station 68. The robotic arm 76 is preferably of the SCARA type, well-known in the field of industrial operations. Other robots suitable for use in the plant 50 are, for example, anthropomorphic robotic arms or Cartesian gantry robots. Preferably, the robotic arm 76 comprises one or more suction cups as end effectors.

[0155] As already mentioned, the plant 50 comprises a pre-assembly station 68 configured to pre-assemble the box 66 starting from the cut blank 64. According to what has been described above with respect to the method, the pre-assembly station 68 is configured to obtain a pre-assembled box 66 starting from a flat blank 64 (preferably of the RSC type). The pre-assembled box 66 has a structural continuity of the side walls, but the upper and lower ends are open and it folds under its own weight.

[0156] In order to achieve this result, starting in particular from a blank RSC or the like, the pre-assembly station 68 must be able to fold the side walls with fins inwards, fold the opposite side walls inwards so as to cover the fins, and join the side walls to the fins. Preferably, the pre-assembly station 68 is automatic and may be of the type described in a patent document entitled PRE-ASSEMBLY STATION FOR PACKAGINGS OF VARIABLE SIZES, developed by the same owner and filed on the same date.

[0157] The above-mentioned automatic pre-assembly station 68 is configured to receive, as input, a blank 64 representing the flat development of at least two boxes 66 of different sizes and to discharge, as output, the pre-assembled boxes. The pre-assembly station 68 comprises a workbench having a width and a length, configured to receive and support the blank 64 in a predetermined orientation, two folding elements 80 movable in the width direction w of the workbench, and pushing means 86 configured to push the blank 64 towards the folding elements 80 and outwards in the length direction l of the workbench. Each of the folding elements 80 comprises a helical screw surface 82 that unfolds around a longitudinal axis b parallel to the direction l.

[0158] Preferably, the folding element 80 will be briefly described hereinafter with particular reference to FIGS. 10 and 11. Each such folding element 80 comprises a first helical screw surface 82 (or helix) and a second substantially flat surface 84. The flat surface 84 extends parallel to the workbench (plane wl).

[0159] The two folding elements 80 of the pre-assembly station 68 have mirror-image functions with respect to each other and preferably also have mirror-image shapes with respect to each other. FIG. 11 shows the left folding element 80. In such a left folding element 82, when proceeding in the l direction (from the inlet to the outlet of the pre-assembly station 68) along the helical screw surface 82, an arc of approximately 180° is drawn. At the proximal end of the folding element 80, the helical screw surface 82 is on the left side of the flat surface 84 and is substantially in the same plane and parallel to the flat surface 84. When proceeding in the direction l, the helical screw surface 82 shows a gradually rotating clockwise deployment. At the distal end of the folding element 80, the helical screw surface 82 returns to a state substantially parallel to the flat surface 84 but is inverted by 180° and superimposed thereon.

[0160] The helical screw surface 82 may define a regular or irregular helix. More specifically, the helical screw surface 82 defines a straight-line section inclined with respect to the flat surface 84 for each section operating in a plane perpendicular to the axis b. The angle included between the helical screw surface 82 and the flat surface 84 varies along the axis b, and this variation can be understood in FIG. 11.

[0161] According to some embodiments, such a variation is uniform along the axis b. In other words, the angle included between the helical screw surface 82 and the flat surface 84 is a linear function of the position along the axis b. Therefore, the helical screw surface 82 defines a regular helix.

[0162] According to other embodiments, the change in angle is not uniform along axis b, and the angle included between the helical screw surface 82 and the flat surface 84 is a non-linear function of the position along axis b. Thus, the helical screw surface 82 defines an irregular helix. For example, in some sections the change in angle may be slow and in other sections it may be rapid. In other words, considering that the planar blank 64 is pushed out along direction l at a constant speed, the angle change of the helical screw surface 82 may create gentle folds in some sections and sharp folds in other sections.

[0163] According to the embodiments shown in the attached FIGS. 10 and 11, the helical screw surface 82 of the folding element 80 is continuous. According to other embodiments (not shown), the helical screw surface 82 of the folding element 80 is discrete and / or discontinuous, which can be obtained, for example, by juxtaposing linear guides.

[0164] According to some embodiments, the surfaces 82 and 84 of the folding element 80 are at least locally provided with a coating suitable for facilitating the sliding of the material constituting the planar blank 64. Preferably, the coating can be made of a low friction coefficient material such as, for example, bronze or polytetrafluoroethylene (PTFE).

[0165] As can be readily understood by those skilled in the art, the right folding element 80 has a mirror-like function with respect to the left folding element and thus preferably also has a mirror-like shape, and is similar to the described left folding element in all respects except for this.

[0166] Downstream of the pre-assembly station 68 on the one hand and downstream of the standby storage 56 on the other hand, the plant 50 comprises a packaging station 70. According to some embodiments, the packaging station 70 is completely manual and an operator is positioned. In this case, the moving means are configured to make available to the operator at the packaging station 70 the pre-assembled box 66 together with the relevant order preferably contained in the container 72.

[0167] Next, the operator must manually complete the assembly of box 66 and proceed to pack the ordered items in the most compact arrangement. For this purpose, the packing station 70 preferably comprises a device configured to provide the operator with instructions regarding the most compact arrangement previously identified, for example through a 3D algorithm. For example, the packing station 70 may comprise a monitor 78 configured to display a dynamic diagram or short video generated by the electronic unit 52 in which various items (identified based on appearance, special numbering, etc.) are virtually positioned within the volume defined by box 66 in the correct order and correct orientation.

[0168] The presence of the operator, in addition to simplifying the packing station 70 significantly, also makes it possible to handle fragile, vulnerable, or potentially dangerous items that cannot be automatically handled.

[0169] According to other embodiments, the packing station 70 has a first automated sub-station and a second manual sub-station where the operator is located. In the first sub-station, the assembly of box 66 is completed in an automated manner by folding the lower closing flap that forms the bottom of box 66. In the second sub-station, the items of the relevant order are manually introduced into box 66. Also in this case, it is preferable to arrange a device configured to provide the operator with instructions regarding the most compact arrangement previously identified, for example through a 3D algorithm.

[0170] Also in this case, the presence of the operator makes it possible to handle fragile, vulnerable, or potentially dangerous items, but the presence of the first automated sub-station reduces the operator's workload and allows for a higher processing speed.

[0171] According to another embodiment, the packaging station 70 is fully automated. Both the completion of the assembly of the box 66 and the introduction of the articles into the box 66 are automatically performed. Thereby, a higher processing speed can be obtained.

[0172] Downstream of the packaging station 70, the plant 50 comprises other moving means configured to make the filled box 66 available for subsequent steps.

[0173] From the above viewpoints, those skilled in the art can well understand that the present invention overcomes the drawbacks emphasized with respect to the prior art.

[0174] In particular, the present invention makes available a method and a plant for manufacturing secondary packaging according to BOD logic, which can handle any kind of article, including those that are fragile, easily damaged, or potentially dangerous.

[0175] Furthermore, the present invention makes available a method and a plant for manufacturing secondary packaging according to BOD logic, which are particularly efficient in terms of the amount of boxes produced and the consumption of packaging material.

[0176] Also, the present invention makes available a method and a plant for manufacturing secondary packaging according to BOD logic, which are very efficient in terms of the cost / performance ratio.

[0177] Finally, the present invention makes available a method and a plant for manufacturing secondary packaging according to BOD logic, which maintain the main functions of the prior art together with the incorporated advantages.

[0178] In conclusion, all details can be replaced by other technically equivalent elements, the features described with respect to a particular embodiment can also be used in other embodiments, and the materials used as well as the accompanying shapes and sizes can be arbitrary according to the requirements of a particular implementation form without departing from the scope of protection of the following claims.

Claims

1. A method for manufacturing secondary packaging according to box-on-demand logic, (100) Each of several items a ｉｊ The steps include providing a plurality of N orders o, (101) Each order ｉ Each item a ｉｊ Regarding the aforementioned item a ｉｊ The steps include defining a linear rectangular prism that is circumscribed around it, (102) Each order ｉ Regarding the most compact item a ｉｊ Steps include identifying the relative arrangement of and (103) Each order ｉ The steps include detecting the size of the quadratic rectangular parallelepiped that circumscribes the most compact arrangement, (104) Each order ｉ The steps include placing it in standby storage (56), (105) For each secondary rectangular parallelepiped, a step of defining a blank (64) that represents a plane development of a box (66) that defines an inner product equal to that of the secondary rectangular parallelepiped ｉ ), and a step of defining a blank (64) that represents a plane development of a box (66) that defines an inner product equal to that of the secondary rectangular parallelepiped (106) The step of adding each blank (64) to the standby list, (107) A step of providing a sheet (60) of packaging material of a predetermined size, (108) In order to minimize waste of packaging material, the steps include optimizing the arrangement on the sheet (60) of at least some of the blanks (64) in the standby list, (109) A step of cutting the blank (64) of the sheet (60), (110) The step of removing the cut blank (64) from the standby list, (111) From the sheet (60) to the blank (64 ｉ The steps to take out ) (112) The removed blank (64 ｉ ) in the box (66 ｉ The steps to assemble ) and (113) The assembled box (66 ｉ ) corresponding to the aforementioned order o ｉ The steps include taking it out of the standby list (56), (114) The box (66 ｉ ) the item a ｉｊ The steps to place and (115) For the subsequent step, the box (66 ｉ The steps include providing, (116) Repeating the steps of taking out a blank (64), assembling the box (66), taking out the corresponding order, placing the items in the box (66), and providing the box (66) for the subsequent steps until the end of the cut blank (64), (117) A step of disposing of the waste packaging material, (118) The step of repeating the method until the end of the order A method for providing this.

2. Each of the aforementioned orders ｉ The most compact item a ｉｊ The step of identifying the relative arrangement of item a ｉｊ The method according to claim 1, which is performed by a recursive optimization algorithm that considers all possible relative arrangements of the quadratic cuboids, slightly modifies the position of each quadratic cuboid relative to other quadratic cuboids, calculates the size of the quadratic cuboids, and selects the most compact arrangement.

3. The aforementioned recursive optimization algorithm is, 3 measurements x ｊ , y ｊ , and z ｊ Each item a is formed by the aforementioned linear rectangular parallelepiped having ｉｊ The steps to define and For each linear rectangular parallelepiped, the measured value x starts from a point called the origin [0;0;0] located at a vertex of the rectangular parallelepiped. ｊ , y ｊ , and z ｊ Identification step, In each linear rectangular parallelepiped, the position [x] relative to the origin ｊ ;0;0], [0;y ｊ ;0], and [0;0;z ｊ The steps include identifying three available vertices corresponding to the aforementioned vertex in ], During the positioning step, the origin of a new linear rectangular parallelepiped is positioned to coincide with one of the available vertices of the already positioned linear rectangular parallelepiped, If the origin of the linear rectangular prism lies on an available vertex, the step is to discard the rectangular prism from the list of linear rectangular prisms to be placed so that the linear rectangular prism is no longer available for subsequent positioning. The method according to claim 2, wherein the method is implemented.

4. The aforementioned optimization algorithm further, A step of storing the volume and size of each calculated quadratic cuboid, A step of verifying whether the quadratic rectangular parallelepiped corresponding to the most compact arrangement of the item has a shape ratio between at least two sizes that fall within the acceptable range, If affirmative, the step of using the quadratic rectangular parallelepiped, or If negative, the step of ignoring the quadratic cuboid, selecting a further cuboid associated with the most compact arrangement excluding the arrangement associated with the ignored quadratic cuboid, and verifying the preceding quadratic cuboid is repeated. The method according to claim 2 or 3, which is assumed to perform the following:

5. The method according to claim 2 or 3, wherein the optimization algorithm further performs the step of adding an offset value to at least one of the sizes of at least one of the items to be placed, the offset value corresponding to the gap required to place protective material for protecting the items while filling the packaging.

6. The method according to claim 1 or 2, further comprising a printing step and / or a folding step between the optimization step (108) and the cutting step (109) of the blank (64).

7. A plant (50) for manufacturing secondary packaging according to box-on-demand logic, An electronic unit (52) comprising a memory module, a refinement module, and a control module configured to provide instructions to the plant (50), A general-purpose storage (54) containing multiple items a, Based on the instruction provided by the electronic unit (52), Take item a from the general-purpose storage (54), The extracted items a are grouped together to form multiple orders o. A handling means configured in such a way, A standby storage (56) configured to maintain the aforementioned order o in a standby state, A supply means (58) configured to make available a sheet (60) of packaging material of a predetermined size based on the instructions provided by the electronic unit (52) and Equipped with, The aforementioned electronic unit (52) further comprises each order o ｉ The system is configured to define blanks (64) in a box (66), add each blank (64) to a standby list, optimize the arrangement of some of the blanks (64) in the standby list on the sheet (60), and remove the cut blanks (64) from the standby list. The aforementioned plant (50) Based on the instruction provided by the electronic unit (52), a specific order is obtained from the sheet (60). ｉ In relation to the above, a cutting station (62) is configured to cut the blank (64) of the box (66) defined by the electronic unit (52), A pre-assembly station (68) configured to pre-assemble the box (66) starting from the cut blank (64), Packaging station (70), Based on the instruction provided by the electronic unit (52), the related order o ｉ A means of transport configured to make the pre-assembled box (66) available for use at the packaging station (70) A plant equipped with even more features.

8. The aforementioned electronic unit (52) further processes each item a ｉｊ Define a linear rectangular parallelepiped circumscribed around it, and for each order oi, the most compact item a ｉｊ The plant according to claim 7, configured to identify the relative arrangement of the elements, detect the size of the quadratic cuboid circumscribing the most compact arrangement, and define the blank (64) of the associated box (66) for each quadratic cuboid.

9. The plant according to claim 7 or 8, further comprising a printing station provided between the supply means (58) and the cutting station (62) for the sheet (60) of the packaging material.

10. The plant according to claim 7 or 8, further comprising a station for turning over the sheet (60).

11. The aforementioned item a ｉｊ The plant according to claim 7 or 8, further comprising a three-dimensional scanning device configured to detect the size of [something].

12. The plant according to claim 7 or 8, wherein the cutting station (62) comprises a numerically controlled machine that performs cutting by laser.

13. The plant according to claim 7 or 8, wherein the cutting station (62) comprises a numerically controlled machine that performs cutting with a blade.

14. The plant according to claim 7 or 8, further comprising a robotic arm (76) suitable for taking the cut blanks (64) from the cutting station (62) and supplying them to the pre-assembly station (68).

15. The aforementioned pre-assembly station (68) is A workbench having width and length, configured to receive and support a blank (64) in a predetermined orientation, The workbench has two folding elements (80) that are movable in the direction w of the width, An extrusion means (86) configured to push the blank (64) toward the folding element and toward the other side in the direction l of the length of the workbench, The plant according to claim 7 or 8, wherein each of the folding elements (80) has a helical screw surface (82) that unfolds around a longitudinal axis b parallel to the direction l.

Images