Packaging material manufacturing apparatus and method for positioning functional units in the packaging material manufacturing apparatus

Abstract

A packaging material production machine (1) is provided, comprising a conveying device (5) configured to guide and move a web of packaging material (3), and a processing system (10). The processing system (10) comprises a functional unit (12) connected to at least one carrier (110), a positioning device (100) comprising a fixed support (120) and a movable bar (130) arranged parallel to said support (120), the at least one carrier (110) comprising an attachment device (160) configured to selectively attach the carrier (110) to only one of said fixed support (120) and said bar (130).

Description

[Technical Field]

[0001] The present invention relates to a packaging material producing machine comprising a positioning device for use therewith. In particular, the present invention relates to an arrangement for linearly positioning a plurality of functional units of a packaging material producing machine. [Background technology]

[0002] The packaging industry has developed sophisticated machines for producing individual packages from packaging material. Typically, the packaging material, which comprises a core layer of bulk material and, optionally, at least a protective layer, coated on both sides with one or more polymer layers, is produced as a continuous web in a high-speed processing process, with the width of the web of packaging material corresponding to multiple lanes. The width of each lane is sized to form the package. After the multiple lanes of packaging material are produced, the packaging material is cut into multiple rolls, each corresponding to a single lane. The resulting rolls of packaging material can be loaded into a web-fed packaging machine or cut into individual blanks that are loaded into a blank-fed packaging machine.

[0003] The packaging machine receives the laminated packaging material and multiple stations perform the necessary processing of the packaging material, which may include, for example, feeding, sterilizing, tubing, filling, sealing, cutting, and final forming, to provide a stream of ready-to-use individual packages.

[0004] In modern machines, the web of packaging material is run at very high speeds, with machine speeds of up to 40,000 packages per hour being commercially available, and high speeds are also utilized during conversion, i.e., during the process of laminating and manufacturing the packaging material, whereby web speeds are typically of the order of, for example, 400 m / min or more.

[0005] The production of a web of packaging material and the transport of the web through a filling machine require highly accurate positional control. For example, the production of packaging material may include providing printed patterns, such as crease lines, pre-cut holes, and register marks and / or decorations. Notably, the printing steps may be performed in separate steps, and the appearance of the final package depends on the placement of different features. Therefore, uncontrollable variations in the positioning of the packaging material during production at the converting plant or filling machine can result in various types of errors.

[0006] Therefore, it is desirable not only to provide high precision alignment between pre-laminated holes and fold lines, but also to provide high precision alignment of printed patterns relative to fold lines, pre-cut holes, external devices such as caps, and previous printed patterns.

[0007] Additionally, it may be desirable to add unique information to the web of packaging material. Such information may relate, for example, to the date of manufacture, the conversion plant, etc., for traceability and / or authentication purposes. Such information may, for example, be provided in coded form or may use readable text or images.

[0008] The unique code can be used to track errors and / or deviations during conversion, and such marks can further facilitate removal of defects.

[0009] Marking of packaging material may be performed for various purposes, i.e., to provide unique information or to provide reference marks for positioning. Reading the reference marks makes it possible to adjust the position of the web of packaging material, in particular the lateral or cross-direction position. Subsequent printing, carried out by continuous printing techniques such as offset printing or inkjet devices, can thus be correctly positioned with respect to the reference marks and therefore also with respect to other features added to the packaging material.

[0010] One system for marking packages is disclosed in the applicant's WO2020008047. In this system, multiple marking devices are arranged across the width of a web of packaging material. Each marking device has a fixed position and is capable of producing laser-ablated marks on the web of packaging material. Multiple laser outputs are independently controlled by a controller to provide dynamic content to the marks.

[0011] While the above-described systems offer significant advantages when printing dynamic content on a web of packaging material, it is crucial to set the correct position of each marking device. Because the correct position is determined by the dimensions and specifications of the packaging material web, the marking device must be repositioned each time a new web of packaging material is produced. Differences between packaging materials may include, for example, different widths, different numbers of lanes, and differences in the lateral position of the marks on each lane. Because the position of the marking device must be set with high precision, repositioning the marking device requires a great deal of effort.

[0012] This problem exists not only in marking systems, but also in other devices that may be used in packaging material or packaging container manufacturing machines, such as cleaning devices, cutting devices, inspection devices, or other printing devices that are positioned across the width of the packaging material, with the correct positioning of each device being determined by the characteristics of the web of packaging material.

[0013] It would therefore be advantageous to provide a positioning device that allows for rapid, accurate, and independent position control of multiple devices distributed across the width of a packaging material. Summary of the Invention [Problem to be solved by the invention]

[0014] It is an object of the present invention to at least partially overcome one or more of the above-identified limitations of the prior art, and in particular to provide a positioning device that can be equipped with multiple functional units and that can independently control the position of each functional unit across the width of the packaging material. [Means for solving the problem]

[0015] To achieve these objectives, a packaging material manufacturing machine is provided that includes a positioning device, the machine comprising: a conveying device configured to guide and move a web of packaging material; and a processing system including functional units connected to at least one carrier and the positioning device, the positioning device including a fixed support and a movable bar arranged parallel to the support, and at least one carrier including an attachment device configured to selectively attach the carrier to only one of the fixed support and the bar.

[0016] The positioning device may further comprise a linear drive connected to the bar, thereby achieving accurate and precise movement of the bar and its associated carrier.

[0017] The positioning device may further comprise a linear encoder, which allows the exact position of each carrier to be continuously monitored, ensuring the correct position of each carrier and triggering any necessary corrections.

[0018] The linear encoder may be located on a position rod arranged parallel to the support and bar. Preferably, the position rod extends along the full width of the fixed support so as to be able to monitor the position of the carrier across the full width of the web of packaging material.

[0019] Each carrier may be provided with a position indicator that is detectable by the linear encoder, and the position of each carrier may therefore be constantly monitored, as the position indicator is always located in detectable proximity to the position rod and the linear encoder.

[0020] The movable bar may be spaced vertically from the fixed support, which provides a rigid support for the carriers, particularly when each carrier is configured with a vertical extension that covers the fixed support and bar.

[0021] The mounting device of each carrier may comprise a support locking unit and a bar locking unit, so that separate locking units can be used to selectively lock the carrier to the fixed support or the movable bar.

[0022] The support locking unit and the bar locking unit may be controlled by a common actuator, which ensures that only one of the locking units is in the locked mode.

[0023] A typical actuator may be a pneumatic valve, providing a simple and robust solution for controlling the locking unit.

[0024] The support locking unit and / or the bar locking unit may be a pneumatic brake cylinder, which can provide a relatively low, but still sufficient, locking force to the carrier.

[0025] The functional unit may be selected from the group consisting of a laser unit, a cutting unit, a cleaning unit, a printing unit, or a camera unit.

[0026] According to a second aspect, there is provided a method of positioning functional units across the width of a web of packaging material on a packaging material producing machine as described above, the method comprising: i) mounting the functional unit on a carrier of a positioning device including a fixed support and a movably arranged bar arranged parallel to the support, and locking the carrier in position relative to the support; ii) releasing the carrier from the support and simultaneously locking the carrier to the bar; iii) moving the bar and carrier to the desired position; iv) locking the carrier to the support and simultaneously releasing the carrier from the bar; This includes:

[0027] Further objects, features, aspects and advantages of the present invention will become apparent from the following detailed description and drawings.

[0028] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: FIG. [Brief explanation of the drawings]

[0029] [Figure 1] 1 is a schematic diagram of a portion of a packaging material manufacturing apparatus having a processing system according to one embodiment. [Figure 2] 1 is a schematic side view of a processing system having a positioning device according to one embodiment. [Figure 3] 1 is a perspective view of a processing system according to one embodiment. [Figure 4] FIG. 1 is a perspective view of a positioning device according to one embodiment. [Figure 5] 5 is a further perspective view of the positioning device shown in FIG. 4. [Figure 6] 1 is a schematic diagram illustrating a method for positioning functional units of a processing system according to an embodiment; DETAILED DESCRIPTION OF THE INVENTION

[0030] Referring to Figure 1, there is shown a schematic representation of a portion of a packaging material production machine 1 as viewed from above. The packaging material production machine 1 may include various stations (not shown) for converting different materials into a web of packaging material 3. To this end, the packaging material production machine 1 may be provided as a converting facility in which a core layer of paper-based material is laminated on both sides with one or more polymer layers. Typically, the packaging material web 3 comprises a core material layer, outer layers, and an inner layer.

[0031] An outer layer is applied to one side of the core material layer and is adapted to provide the outer surface of the package to be produced, with this outer surface and outer layer facing the periphery of the final package produced from the web of packaging material 3. An inner layer is applied to the other side of the core material layer and is adapted to provide the inner surface of the final package to be produced that will contact the product contained in the package.

[0032] The core material may be a sheet to provide rigidity to the web of packaging material 3 and may preferably be made of a material such as paperboard or cardboard.

[0033] The outer layer may comprise at least one layer of polymeric material that is applied to the core material layer in a lamination process, and one of the layers that make up the outer layer may be a decorative layer that provides the exterior appearance of the resulting package.

[0034] The inner part of the laminate packaging material may comprise at least one layer of polymeric material opposite the inner side of the core material layer. The inner part of the packaging material intended for the inside of the finished package may comprise, for example, (starting from the core material layer) a laminate layer, a protective layer such as aluminum foil that acts as a barrier against gases such as oxygen gas, and a sealing layer. The laminate layer allows adhesion between the core material and the protective layer, and the sealing layer allows heat sealing of the package.

[0035] The polymer layer of the web of packaging material 3 may be any suitable type of polymer material, particularly suitable for contact with food products, preferably a thermoplastic material such as a polyolefin, such as polyethylene.

[0036] As shown in Figure 1, the packaging material production machine 1 comprises a conveying device 5 and a processing system 10. The conveying device 5, shown here diagrammatically as rollers, is configured to guide and move the web of packaging material 3 in an advance direction indicated by a block arrow.

[0037] The processing system 10 comprises a positioning device 100 extending across the width of the web of packaging material 3 and a plurality of functional units 12 connected to the positioning device 100. Each functional unit 12 is configured to act on or towards the web of packaging material 3 passing by.

[0038] As described further below, each functional unit 12 is connected to positioning apparatus 100 by a carrier 110. Each carrier 110 is preferably universal, i.e., capable of being mechanically connected to a wide variety of functional units 12 without substantial modification. Thus, in one embodiment, carrier 110 is only mechanically connected to functional unit 12, whereby additional connections for functional unit 12, such as power, signals, etc., are provided on the functional unit 12 itself.

[0039] Positioning apparatus 100 further comprises a fixed support 120 and a movable bar 130. Each carrier 110 is coupled to either the fixed support 120 or the bar 130, as further described below.

[0040] 1, the web of packaging material 3 includes eight lanes 7. Each lane 7 has a width corresponding to the width required to form an individual package. Thus, when the web of packaging material 3 is produced, it is cut into eight portions, each portion corresponding to a single lane 7, whereby the single portion is used as input material to a package-making machine (not shown).

[0041] Processing system 10 is configured to control the lateral position of each carrier 110 and its associated functional unit 12. Typically, each functional unit 12 has a fixed position during the production of a particular web of packaging material 3. However, if a web of another type of packaging material 3 is produced, for example, a web having a different width or a different number of lanes 7, the number and / or positions of carriers 110 must be adjusted accordingly.

[0042] Therefore, the processing system 10 is preferably connected to a control unit 20 configured to control the operation of the positioning device 100, and optionally also to control the operation of the functional units 12. The control unit 20 in one embodiment comprises a first module 22 connected to the positioning device 100 and configured to receive a signal S1 corresponding to the actual lateral position of the carriers 110, to send a signal S2 for changing the mode of one or more carriers 110 from a fixed mode to a movable mode, and to send a signal S3 for moving a carrier 110 in the movable mode to a desired position. In addition to the first module 22, the control unit 20 may comprise a second module 24 connected to the functional units 12 and configured to send a control signal S4 to them.

[0043] In one example, processing system 10 is configured to provide laser marks 4 on the web of packaging material 3. In the embodiment shown in Figure 1, the laser marks 4 are provided on the web of packaging material 3 located downstream of processing system 10. In such an embodiment, each functional unit 12 is a laser head that is activated upon receiving control signal S4 to irradiate the web of packaging material 3 with light, thereby ablating the visible marks 4.

[0044] Laser marking of a web of packaging material 3 has been described by the applicant, for example in WO2020008047, and the techniques and procedures for this process will not be described further here.

[0045] 2 shows the processing system 10 in more detail. The positioning device 100, which forms part of the processing system 10, is designed so that a fixed support 120 and a movable bar 130 extend parallel to each other and at a vertical distance from each other. The fixed support 120 is here in the form of a rigid body and extends across the entire width of the web of packaging material 3, or at least to cover the width that can be used by the functional units 12. Preferably, the movable bar 130 also extends across the entire width of the web of packaging material 3, but it may be longer than the entire width of the web of packaging material 3, or may be sufficient to cover only a portion of the width of the web of packaging material 3, as long as the movable bar 130 can move to the respective positions of the carrier 110 and the functional units 12 connected thereto.

[0046] An example of a processing system 10 is shown in Figure 3. Here, a positioning device 100 comprises four carriers 110 spaced apart along the extension of the positioning device 100. Each carrier 110 is connected to a functional unit 12a-e.

[0047] The functional units 12a-e may be the same or different. For example, each functional unit 12a-e may be a laser head 12a, a cleaning device 12b, a cutting device 12c, an inspection device 12d such as a camera, or another printing device 12e such as an inkjet printing device. In other embodiments, a single processing system 10 may have different functional units 12a-e.

[0048] As shown in Figure 3 and further described with reference to Figures 4 and 5, fixed support 120 is disposed at the bottom and center of positioning device 100. Movable bar 130 is disposed vertically above fixed support 120 and extends parallel to substantially the entire width of fixed support 120. Positioning device 100 further includes position rod 140. Position rod 140 is disposed parallel to fixed support 120 and movable bar 130, and the length of position rod 140 is substantially equal to the length of fixed support 120.

[0049] Each carrier 110 is movable along the fixed support 120 by the movable bar 130, as well as the position rod 140. To this end, each carrier 110 is configured to be selectively coupled to either the fixed support 120 or the movable bar 130. Once a carrier 110 is locked to the movable bar 130, a drive unit 150 is activated to drive the carrier 110 to a desired position, as shown in FIG. 4 . In some embodiments, the same carrier 110 can be driven several times to reach a desired position. To accomplish this, the carrier may be unlocked from the movable bar 130 while locked to the fixed support 120; after the movable bar 130 is in its initial position, the carrier 110 may again be locked to the movable bar 130, unlocked from the fixed support 120, and driven again by the drive unit 150. The drive unit 150 is preferably a linear motor configured to control the lateral movement of the movable bar 130 such that one or more carriers 110 are moved from an actual position along the position rod 140 to a desired position.

[0050] For accurate positioning of the carriers 110, the position rods 140 are provided with linear encoders 142. The linear encoders 142 extend along the length of the position rods 140 and are configured to detect the position of the position indicators 112 (see FIG. 5). Each carrier 110 is provided with such a position indicator 112, for example in the form of a magnet.

[0051] 5, further details of the positioning device 100 are shown. Each carrier 110 is provided with a mounting device 160 for selectively securing the carrier 110 to the fixed support 120 or the movable bar 130.

[0052] In the illustrated embodiment, the mounting device 160 includes a support locking unit 162 configured to secure the carrier 110 to the fixed support 120 and a bar locking unit 164 configured to secure the carrier 110 to the movable bar 130. The support locking unit 162 and the bar locking unit 164 are preferably controlled by a common actuator 166. In one embodiment, each of the support locking unit 162 and the bar locking unit 164 is in the form of a brake cylinder having brake pads 163, 165 movable toward and away from the fixed support 120 and the movable bar 130, respectively. The common actuator 166 is preferably a pneumatic valve connected to a pressurized air supply. The actuator 166 either activates the brake cylinder 162 acting on the fixed support 120 or the brake cylinder 164 acting on the movable bar 130. Thus, each carrier 110 is always in either a locked mode or a movable mode. In the locked mode, the actuator 166 activates the brake cylinder 162 acting on the fixed support 120, causing the brake pad 163 to press against the preferably planar surface of the fixed support 120. Friction between the brake pad 163 and the fixed support 120 causes the carrier 110 to have a fixed position. Upon receiving the control signal S2 (see FIG. 1), the carrier switches its current mode from the locked mode to the movable mode. The actuator 166 thus releases pressure from the brake cylinder 162 and instead switches to act on the brake cylinder 164 acting on the movable bar 130. The associated brake pad 165 is then pressed against the preferably planar surface of the movable bar 130, and the friction between the brake pad 165 and the movable bar 130 locks the carrier 110 to the movable bar 130. Controlling the movable bar 130 to move simply causes a corresponding movement of one or more carriers 110 currently controlled in the movable mode.

[0053] During movement of the carrier 110, the magnet 112, shown as a recessed member partially surrounding the position rod 140, can be read by the linear encoder 142 so that the exact position of the carrier 110 is constantly monitored. Once the desired position of the moved carrier 110 is reached, the actuator 166 switches again to change the mode of the moved carrier 110 from its current movable mode to a locked mode.

[0054] To provide for smooth movement of the carrier 110 along the fixed support 120, the fixed support 120 includes an upper guide rail 122 and a lower guide rail 124 vertically spaced from the upper guide rail 122. The guide rails 122, 124 are arranged parallel to one another and extend along the width of the fixed support 120. Each carrier 100 further includes linear bearings 114, 115 that slide relative to the guide rails 122, 124. The upper linear bearing 115 is arranged to slide relative to the upper guide rail 122, and the lower linear bearing 114 is arranged to slide relative to the lower guide rail 124.

[0055] 5, the fixed support 120 further comprises an upper guide rail 126 on which the linear bearings 132 of the movable bar 130 slide, thus allowing a low-friction and well-defined movement of the movable bar 130 relative to the fixed support 120.

[0056] 6, a method 200 is shown schematically. The method 200 is performed to position functional units across the width of a web of packaging material. As explained above, a functional unit may be any suitable unit for performing an action on a web of packaging material passing through the functional unit. A functional unit may be, for example, a laser head, a cleaning unit, a cutting unit, an inspection unit, or a printing device.

[0057] The method 200 comprises a first step 202 of mounting a functional unit on a carrier of a positioning device comprising a fixed support and a movable bar arranged parallel to the support, wherein the carrier is locked in position relative to the support.

[0058] The next step, 204, involves locking the carrier to the bar and simultaneously releasing the carrier from the support. Preferably, this step is performed by switching the actuators connected to the two brake cylinders, as explained above.

[0059] In step 206, the bar and the carrier locked to the bar are moved to the desired position, and then the process proceeds to step 208, where the carrier is released from the bar and simultaneously locked to the support.

[0060] The above-described embodiment has proven to be very advantageous for the accurate positioning and repositioning of functional units 12 across the entire web of packaging material 3. Typically, the number of carriers 110 for the positioning device is between 2 and 20, for example between 3 and 15. By providing the positioning device, an accuracy of 0.2 mm across the entire width of the web of packaging material 3 can be achieved.

[0061] Advantageously, only one actuator, for example a pneumatic valve 166, operates both brake cylinders 162, 164, so that the carrier 110 is always locked to either the fixed support 120 or the movable bar 130. Preferably, the carrier 110 does not move freely on its own.

[0062] The control unit 20 is preferably programmed to provide continuous operation, i.e., the positions of all carriers 110 are monitored and optionally automatically corrected as long as the positioning device 100 is operating.

[0063] When brake pads 163, 165 are used, the force required to overcome friction has proven to be relatively small, such as in the range of 30-50 N. Thus, exceeding this force will result in movement of carrier 110 rather than damage to carrier 110.

[0064] An important advantage of this is that the positioning device can be operated even when the packaging material production machine 1 is stopped. Even if the carrier moves and an operator gets too close to the carrier, the force is so small that it will not harm the operator.

[0065] From the foregoing description, while various embodiments of the present invention have been described and shown, the invention is not limited thereto and may be embodied in other ways within the scope of the subject matter defined in the following claims.

Claims

1. A packaging material manufacturing machine (1) comprising a conveying device (5) configured to guide and move a web of packaging material (3) and a processing system (10), The processing system (10) comprises a functional unit (12) connected to at least one carrier (110), and a positioning device (100) comprising a fixed support (120) and a movable bar (130) arranged parallel to the fixed support (120), The carrier (110) comprises a mounting device (160) configured to selectively mount the carrier (110) to only one of the fixed support (120) and the bar (130). Packaging material manufacturing machine (1).

2. the positioning device (100) further comprises a linear drive (150) coupled to the bar (130); A packaging material manufacturing machine (1) according to claim 1.

3. The positioning device (100) further comprises a linear encoder (142). A packaging material manufacturing machine (1) according to claim 1 or 2.

4. The linear encoder (142) is disposed on a position rod (140) disposed parallel to the fixed support (120) and the bar (130). A packaging material manufacturing machine (1) according to claim 3.

5. Each carrier (110) is provided with a position indicator (112) detectable by said linear encoder (142); A packaging material manufacturing machine (1) according to claim 3 or 4.

6. The bar (130) is positioned at a vertical distance from the fixed support (120). A packaging material manufacturing machine (1) according to any one of claims 1 to 5.

7. Each carrier (110) has a vertical extension that covers the fixed support (120) and the bar (130). A packaging material manufacturing machine (1) according to any one of claims 1 to 6.

8. The mounting device (160) of each carrier (110) comprises a support lock unit (162) and a bar lock unit (164); A packaging material manufacturing machine (1) according to any one of claims 1 to 7.

9. The support lock unit (162) and the bar lock unit (164) are controlled by a common actuator (166). A packaging material manufacturing machine (1) according to claim 8.

10. the common actuator (166) is a pneumatic valve; A packaging material manufacturing machine (1) according to claim 9.

11. the support lock unit (162) and / or the bar lock unit (164) are pneumatic brake cylinders; A packaging material manufacturing machine (1) according to any one of claims 8 to 10.

12. the functional unit (12) is selected from the group consisting of a laser unit (12a), a cutting unit (12b), a cleaning unit (12c), a camera unit (12d), or a printing unit (12e); A packaging material manufacturing machine (1) according to any one of claims 1 to 11.

13. A method for positioning functional units across the width of a web of packaging material in a packaging material manufacturing machine according to any one of claims 1 to 12, comprising the steps of: i) mounting the functional unit on a carrier of a positioning device including a fixed support and a movably arranged bar arranged parallel to the fixed support, and locking the carrier in a predetermined position relative to the fixed support; ii) releasing the carrier from the fixed support and simultaneously locking the carrier to the bar; iii) moving the bar and carrier to a desired position; iv) locking the carrier to the fixed support and simultaneously releasing the carrier from the bar; The method includes:

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