Box-making apparatus and box-making method

Abstract

To make it possible to manufacture boxes of different height dimensions without replacing inner flap pushing up means.SOLUTION: There are provided punch holding means 12 for holding a punch member PR on a blank sheet 10, inner flap push-up means 25 that bends a pair of abutting inner flaps 107 by relative movement with respect to the punch member PR in the bending direction (Z direction), front and rear wall die means 24 that bends a rear wall section 103 and a pair of abutting outer flaps 108 by relative movement to the punch member PR in the bending direction, abutting the rear wall section 103 and pushing forward in the bending direction. The inner flap push-up means 25 is configured to be able to adjust the relative height δ with respect to the front and rear wall die means 24, when the relative height δ is greater than or equal to a predetermined relative height, when bending the rear wall section 103 and the pair of abutting outer flaps 107, the relative height δ of the inner flap push-up means 25 in relation to the pressing surface of the punch member PR is limited to a predetermined value or less.SELECTED DRAWING: Figure 2

Description

Technical Field

[0005]

[0001] The present disclosure relates to a packaging device for packaging products, and particularly to a case-making device that performs an operation of making a semi-case carton filled with products from a blank sheet.

Background Art

[0002] In recent years, in a manufacturing line for packaging products, a case-making and packaging process of making a semi-case carton filled with products from a blank sheet of a wraparound-type carton has been introduced. For example, Patent Document 1 discloses a case-making device used in this process.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the case of a carton with a short height dimension, the inner flap pushing-up means extending from the rear wall surface portion to both sides in the width direction may contact and get caught by the butting outer flaps extending from the lid surface portion to both sides in the width direction, resulting in a problem that the packaging box is damaged during case-making. To avoid this, it was necessary to set the height of the inner flap pushing-up means low.

[0005] However, in this case, a problem occurs that the inner flap of a carton with a long height dimension cannot be sufficiently bent. Therefore, it is necessary to use inner flap pushing-up means with different heights according to the height dimension of the carton, which causes a workload for change and a factor that reduces production efficiency.

[0006] This disclosure has been made in view of the above-mentioned problems, and aims to provide a box-making apparatus and method that enables the production of boxes of different heights without replacing the internal flap lifting means, and that suppresses damage to the packaging box during box production. [Means for solving the problem]

[0007] A box-making apparatus according to one aspect of the present disclosure is a box-making apparatus that folds a blank sheet along a folding line to form an open half-box carton, wherein the blank sheet comprises a front wall portion, a base portion, a rear wall portion, along a first direction Lid surface A portion, a pair of butt-joint inner flaps sandwiching the rear wall portion in a second direction perpendicular to the first direction, and in the second direction Lid surface The blank sheet is mounted on a base that includes a pair of butt-joint outer flaps sandwiching a section, a punch holding means for holding a punch member mounted on the base surface of the blank sheet, an inner flap pushing means that, by relative movement relative to the punch member in the bending direction opposite to the punch member, comes into contact with the pair of butt-joint inner flaps and pushes forward in the bending direction, thereby bending the pair of butt-joint inner flaps in the bending direction at the base fold line, and by relative movement relative to the punch member in the bending direction, comes into contact with the rear wall surface The device includes a die means that pushes forward in the bending direction to bend the rear wall surface and the pair of butt-joint outer flaps in the bending direction at the bending line at the base of the rear wall surface after the pair of butt-joint inner flaps have been bent, and the inner flap pushing means is configured to adjust the relative height with respect to the die means, and when the relative height is greater than or equal to a predetermined relative height, the relative height of the inner flap pushing means with respect to the punch member is limited to a predetermined value or less when bending the rear wall surface and the pair of butt-joint outer flaps. [Effects of the Invention]

[0008] According to one aspect of the present disclosure, a box-making apparatus and method can be provided that enables the production of cartons of different heights without replacing the internal flap lifting means, and also suppresses damage to the packaging box during production. [Brief explanation of the drawing]

[0009] [Figure 1] (a) is a plan view of a wrap-around carton for manufacturing half-cartons supplied to the box-making apparatus 1 according to the embodiment, and (b) is a perspective view of the half-carton supplied to the box-making apparatus 1. [Figure 2] (a) and (b) are perspective views showing the box-making apparatus 1 according to the embodiment. [Figure 3] This is a plan view showing the configuration of the box-making apparatus 1. [Figure 4] This is a front view showing the configuration of the box-making apparatus 1. [Figure 5] This is a cross-sectional view taken at section AA in Figure 3. [Figure 6] This is a left side view showing the configuration of the box-making apparatus 1. [Figure 7] This is a perspective view showing the box-making device 1 in the process of manufacturing a half-box carton 100H with a longer height dimension. [Figure 8] This is a perspective view showing the box-making device 1 in the process of manufacturing a 100L half-box carton with a shorter height dimension. [Figure 9] This is a perspective view showing the process of manufacturing half-cartons using a conventional carton-making machine. [Figure 10] (a) is a left side view illustrating the box-making operation of the box-making device 1 for half-box cartons 100H, and (b) is a schematic front view. [Figure 11] (a) is a left side view illustrating the box-making operation of the box-making device 1 for half-box cartons 100H, and (b) is a schematic front view. [Figure 12] (a) is a left side view illustrating the box-making operation of the box-making device 1 for half-box cartons 100H, and (b) is a schematic front view. [Figure 13](a) is a left side view illustrating the box-making operation of the box-making device 1 for half-box cartons 100H, and (b) is a schematic front view. [Figure 14] (a) is a left side view illustrating the box-making operation of the box-making device 1 for a half-box carton of 100L, and (b) is a schematic front view. [Figure 15] (a) is a left side view illustrating the box-making operation of the box-making device 1 for a half-box carton of 100L, and (b) is a schematic front view. [Modes for carrying out the invention]

[0010] ≪Outline of the modes for carrying out the invention≫ The box-making apparatus according to the embodiment of this disclosure is a box-making apparatus that folds a blank sheet along a folding line to form an open half-box carton, wherein the blank sheet has a front wall portion, a base portion, a rear wall portion, along a first direction Lid surface A portion, a pair of butt-joint inner flaps sandwiching the rear wall portion in a second direction perpendicular to the first direction, and in the second direction Lid surfaceIt includes a pair of butting outer flaps that sandwich a portion, a base on which the blank sheet is placed, punch holding means for holding a punch member placed on the base surface of the blank sheet, and by relative movement of the punch member in a bending direction relative to the punch member, it abuts against the pair of butting inner flaps and pushes forward in the bending direction to bend the pair of butting inner flaps in the bending direction at the root bending line respectively by inner flap pushing means, and by relative movement of the punch member in the bending direction, it abuts against the rear wall surface and pushes forward in the bending direction to bend the rear wall surface and the pair of butting outer flaps in the bending direction at the root bending line of the rear wall surface after the pair of butting inner flaps are bent, and has die means, wherein the inner flap pushing means is configured to be able to adjust the relative height with respect to the die means, and when the relative height is a predetermined relative height or more, when bending the rear wall surface portion and the pair of butting outer flaps, the relative height of the inner flap pushing means with respect to the pressing surface of the punch member is limited to a predetermined value or less.

[0011] Also, in another aspect, in the aspect described in any of the above, the inner flap pushing means may be configured to reduce the relative height as the relative movement in the bending direction of the die means occurs when the relative height is a predetermined relative height or more and when bending the rear wall surface portion and the pair of butting outer flaps, so as to limit the relative movement in the bending direction.

[0012] With such a configuration, it is possible to manufacture cartons with different height dimensions without replacing the inner flap pushing means, and a carton manufacturing apparatus that suppresses damage to the packaging box during carton manufacturing can be realized.

[0013] Also, the carton manufacturing method according to the embodiment in the present disclosure is a carton manufacturing method in which a blank sheet is bent along a bending line to form an open-top half carton, and the blank sheet includes a front wall surface portion, a base surface portion, a rear wall surface portion along a first direction [[ID=1A portion, a pair of butt-joint inner flaps sandwiching the rear wall portion in a second direction perpendicular to the first direction, and in the second direction Lid surface The process includes: placing the blank sheet on a base, holding the punch member placed on the base surface of the blank sheet, moving the inner flap pushing means relative to the punch member in the bending direction opposite to the punch member, contacting the pair of butt inner flaps, and pushing forward in the bending direction, thereby bending the pair of butt inner flaps in the bending direction at the base fold line, and moving the die means relative to the punch member in the bending direction, contacting the rear wall surface The process involves pushing forward in the bending direction to bend the pair of butt-joint inner flaps, and after bending the pair of butt-joint outer flaps, the rear wall surface and the pair of butt-joint outer flaps are bent in the bending direction at the bending line at the base of the rear wall surface. The inner flap pushing means is configured to adjust its relative height with respect to the die means, and when the relative height is greater than or equal to a predetermined relative height, in the process of bending the rear wall surface and the pair of butt-joint outer flaps, the relative height of the inner flap pushing means with respect to the pressing surface of the punch member is limited to a predetermined value or less.

[0014] In another embodiment, in any of the embodiments described above, the inner flap pushing means may be configured such that, when the relative height is greater than or equal to a predetermined relative height, in the process of bending the rear wall surface and the pair of abutting outer flaps, the relative height is reduced as the die means moves relative to the bending direction, thereby limiting the relative movement in the bending direction.

[0015] This configuration makes it possible to manufacture cartons of different heights without replacing the internal flap lifting mechanism, and also realizes a carton manufacturing method that suppresses damage to the packaging box during manufacturing.

[0016] <Embodiment> The configuration of the box-making apparatus 1 according to the embodiment will be described with reference to the drawings. Herein, in this specification, the X direction, Y direction, and Z direction in each figure may be referred to as the width direction, depth direction, and height direction, respectively, and the positive direction of the height direction may be referred to as the "up" direction and the negative direction as the "down" direction.

[0017] Furthermore, the scale of the components in each drawing is not necessarily the same as the actual scale. Also, in this specification, the symbol "~" used to indicate a numerical range includes the values ​​at both ends. In addition, the materials, numerical values, etc. described in this embodiment are merely examples of preferred materials and are not limiting. Furthermore, modifications can be made as appropriate without departing from the scope of the technical idea of ​​this disclosure. In addition, combinations of parts of the configuration with other embodiments are possible as long as they do not result in inconsistencies.

[0018] <Composition: Blank sheet, half-box carton> The configuration of a blank sheet 100 supplied to a box-making apparatus 1 according to one embodiment of this disclosure, and a half-box carton 100A formed from the blank sheet 100, will be described below.

[0019] Figure 1(a) is a plan view of a wrap-around carton used to manufacture half-box cartons supplied to the box-making apparatus 1 according to the embodiment.

[0020] The blank sheet 100 is a blank sheet of cardboard or corrugated cardboard unfolded into a sheet, and is divided into multiple surfaces that make up a three-dimensional object by folding lines, and is folded along the folding lines to form a box shape.

[0021] Figure 1(a) shows a blank sheet 100, which is mainly composed of a base portion 101, a front wall portion 102, a rear wall portion 103, and a lid portion 104. The base portion 101, front wall portion 102, rear wall portion 103, and lid portion 104 each have flaps 105L to 108L that form the left wall and flaps 105R to 108R that form the right wall, respectively, connected across a fold line. In addition, the lid portion 104 has a flap 109 that overlaps the outer surface of the front wall portion 102 after box manufacturing and serves as an adhesive area, connected across a fold line.

[0022] Figure 1(b) is a perspective view of a half-box carton 100A manufactured from a blank sheet 100 by a box-making device 1. As shown in Figure 1(b), the half-box carton 100A is a half-box carton with a lid, formed by folding the front wall portion 102, rear wall portion 103, flaps 105L~107L, and flaps 105R~107R of the blank sheet 100 upward along their respective bending lines, with the base portion 101 serving as the bottom surface. The base portion 101 of the blank sheet 100 serves as the reference surface in box manufacturing.

[0023] Furthermore, flaps 106L and 107L extend inside flap 105L, and flaps 106R and 107R extend inside flap 105R, forming the left and right walls, respectively. Thus, flaps 106L and 107L, and flaps 106R and 107R, each constitute a pair of butted inner flaps. Additionally, flaps 105L and 108L, and flaps 105R and 108R, each constitute a pair of butted outer flaps.

[0024] This half-box carton 100A is constructed by applying adhesive to a portion of the inner surface of flaps 105L, 105R, 108L, 108R, and 109, bonding the inner surface of flap 105L to the outer surface of side walls 106L and 107L, and bonding the inner surface of flap 105R to the outer surface of side walls 106R and 107R.

[0025] Then, in the box-making process, the inner surface of flap 109 is bonded to the outer surface of front wall portion 102, the inner surfaces of flaps 105L and 108L are bonded to the outer surfaces of flaps 106L and 107L that form the left wall, and the inner surfaces of flaps 105R and 108R are bonded to the outer surfaces of flaps 106R and 107R that form the right wall, thereby forming a carton containing the product.

[0026] <About the configuration of the box-making apparatus 1> Next, the configuration of the box-making apparatus 1 according to the embodiment will be described with reference to the drawings.

[0027] Figures 2(a) and 2(b) are perspective views showing the configuration of the box-making apparatus 1, Figure 3 is a plan view, Figure 4 is a front view, Figure 5 is a true cross-sectional view cut along cross-section AA in Figure 3, and Figure 6 is a left side view.

[0028] (Overall structure) The box-making apparatus 1 is a mechanism unit that folds a wrap-around type carton blank sheet 100 along the folding lines to form an open-lid half-box carton A.

[0029] As shown in Figures 2-6, the box-making apparatus 1 includes a base 40 on which a blank sheet 100 is placed, a product supply and holding means 10 for placing and holding the product PR on the base surface portion 101 of the blank sheet 100, and a die mechanism unit 20 (female mold).

[0030] Furthermore, the box-making apparatus 1 includes a control unit 50 that controls the product supply and holding means 10 and the die mechanism unit 20, and each element is controlled to operate in conjunction with the others. The control unit is implemented as a computer, for example, equipped with a general CPU (Central Processing Unit), RAM (Random Access Memory), and a program executed on them. The control unit reads the control program for the box-making apparatus 1 from a storage device or the like into the RAM and executes it, thereby controlling each element constituting the box-making apparatus 1 to operate in conjunction with others and realizing the functions of the box-making apparatus 1.

[0031] In this embodiment, the blank sheet 100 to be manufactured will be described using a blank sheet of a wrap-around shaped carton for manufacturing a half-carton 100A as an example of the blank sheet 100 to be manufactured, and the configuration of the box-making apparatus 1 will be explained. However, the blank sheet 100 that can be used is one that has a butt-joint inner flap and a butt-joint outer flap, and other shapes such as a straight type, in addition to the wrap-around type, may also be used.

[0032] (Overview of the structure of each section) The following describes the general configuration of each part of the box-making apparatus 1.

[0033] [Product PR] Product PR is the contents of the blank sheet 100, and can be a product that is commonly distributed, such as processed foods, confectionery, or daily necessities, packed in a cubic or rectangular box. The box-making apparatus 1 can use multiple types of product PR with different dimensions in the X, Y, and Z directions. In this case, a blank sheet 100 corresponding to the size of the product PR is prepared, and the blank sheet 100 is used to form a box with the product PR as the punching member (male mold), thereby forming a half-box carton A containing the product PR.

[0034] [Product supply holding means 10] The product supply and holding means 10 is a mechanism unit that places the product PR on the base surface portion 101 of the blank sheet 100 placed on the base 40, and holds the top surface of the placed product PR during the box-making operation.

[0035] The product supply and holding means 10 includes a work head 11, a product holding means 12, a product supply means 13, a robot hand 14, a robot arm 15, a robot body base 16, and a product transport table 17.

[0036] The robot arm 15 is a ceiling-mounted robot arm that is suspended and extended from a member located above the robot arm 15 itself, such as a robot body base 16 installed on the ceiling of the equipment.

[0037] The robot arm 15 can use a mechanism that allows the work head 11 to rotatably support the work head 11 via the robot hand 14, and that enables the work head 11, which holds the product holding means 12 and product supply means 13, to move to a predetermined position in a two-dimensional space consisting of the YZ plane.

[0038] Furthermore, the robot arm 15 includes a drive mechanism (e.g., a motor) and is driven based on a control signal issued from a control unit (not shown), allowing it to change the position of the work head 11 in the YZ plane.

[0039] The robot hand 14 is a holding means that moves in a two-dimensional space in the YZ plane by being connected to the tip of the robot arm 15, and holds the work head 11.

[0040] The work head 11 is a structural member rotatably held by a robot hand 14 connected to the tip of a robot arm 15, with various mechanical members constituting the product holding means 12 and product supply means 13 erected from the bottom surface downwards. Function is achieved by moving these components to desired positions in two-dimensional space in the YZ direction.

[0041] The product supply means 13 is a product holding member for placing the product PR on the base surface portion 101 of the blank sheet 100 placed on the base 40, and consists of a rear holding portion 132, a front holding portion 133, a pair of side holding portions 134L and R (sometimes collectively referred to as "side holding portion 134"), and a position variable mechanism 131 for changing the position of these holding portions according to the size of the product PR.

[0042] The product PR is transported by the work head 11, which slides the product transport table 17 to the base surface 101 of the blank sheet 100 while surrounded by the rear holding portion 132, the front holding portion 133, and the side holding portion 134 in a plan view.

[0043] The product holding means 12 is a pressing means that holds the top surface of the product PR placed on the base surface portion 101 of the blank sheet 100 during the box-making operation, and consists of a basic holding portion 122 and an additional holding portion 121.

[0044] The basic holding portion 122 is a structural member that is fixedly extended from the lower surface of the work head 11, which operates regardless of the size of the top surface of the product PR in the X direction, and contacts the top surface of the product PR.

[0045] The additional holding part 121 is a structural member that is attached to the basic holding part 122 in the X direction and operates when the size of the top surface of the product PR in the X direction is large, and contacts the top surface of the product PR together with the basic holding part 122.

[0046] As shown in Figure 4, the additional holding part 121 has a pressing part 121a, a slide arm 121b that holds the pressing part 121a, and a slide mechanism 121c that allows the slide arm 121b to reciprocate in the Z direction, so that the pressing part 121a can reciprocate in the Z direction. This allows it to be retracted upward to a height where it does not come into contact with the top surface of the product PR when not in operation.

[0047] The product supply and holding means 10, which has the above configuration, operates to conform to the size of the product PR based on instructions from the control unit 50, places the product PR on the base surface 101 of the blank sheet 100 placed on the base 40, and holds the top surface of the placed product PR during the box-making operation.

[0048] [Die mechanism unit 20] The die mechanism unit 20 is a female die mechanism that, during box making, uses product PR, which corresponds to the punch member (male die), as the punch member (male die), and moves in the bending direction (Z direction (upward) in this specification) relative to the punch member, to fold the blank sheet 100 along the folding line and move to form an open half-box carton A.

[0049] For example, as shown in Figure 3, the die mechanism unit 20 includes, on each of the four sides of the base surface portion 101 of the blank sheet 100, two front and rear wall die means 24L, R (sometimes collectively referred to as "front and rear wall die means 24") located on the front wall portion 102 side, two front and rear wall die means 24L, R located on the rear wall portion 103 side, and two side wall die means 27L, R (sometimes collectively referred to as "side wall die means 27") located on the flap 105L, R side.

[0050] Furthermore, the device includes a fixed base 22 and a movable base 23 on which these die means 24 and 27 are mounted, and two guide rails 21 that guide the reciprocating movement of the movable base 23 in the X direction.

[0051] Furthermore, the blank sheet 100 is equipped with a pair of left and right inner flap pushing means 26L, R (sometimes collectively referred to as "inner flap pushing means 26") located on the front wall portion 102 side, and a pair of left and right inner flap pushing means 25L, R (sometimes collectively referred to as "inner flap pushing means 25") located on the rear wall portion 103 side.

[0052] The guide rail 21 is a long rail member extending in the X direction, with a fixed base 22 and a movable base 23 mounted on top of it, and two of them are arranged in the Y direction, flanking the base 40. By moving the guide rail 21 in the Z direction, the members on the fixed base 22 and the movable base 23 function as dies during box making (Mz in Figures 2, 4-6).

[0053] The fixed base 22 is a structural member positioned at the X-direction end of each guide rail 21.

[0054] On the fixed base 22 located on the front wall surface 102 side of the blank sheet 100, front and rear wall die means 24L, inner flap pushing means 25L, and side wall die means 27L are erected. Also, on the fixed base 22 located on the rear wall surface 103 side of the blank sheet 100, front and rear wall die means 24L, inner flap pushing means 25L, and side wall die means 27L are erected.

[0055] The movable base 23 is a structural member arranged on each guide rail 21 so as to be able to reciprocate in the X direction. Based on instructions from the control unit 50, it moves along the guide rail 21 in the X direction to match the size of the product PR (not shown) in the X direction (Mx in Figures 2-5).

[0056] On the four sides of the base surface portion 101 of the blank sheet 100, the movable base portion 23 located on the front wall surface portion 102 side is equipped with front and rear wall die means 24R, an inner flap pushing means 25R, and a side wall die means 27R. On the movable base portion 23 located on the rear wall surface portion 103 side, the front and rear wall die means 24R, an inner flap pushing means 25R, and a side wall die means 27R are also equipped.

[0057] The front and rear wall die means 24 located on the front wall surface 102 side are receiving means for bending the front wall surface 102 in the Z direction at the base bending line by contacting the front wall surface 102 and pushing it in the Z direction as the guide rail 21 rises. Two front and rear wall die means 24L are erected on the fixed base 22 located on the front wall surface 102 side, and two front and rear wall die means 24R are erected on the movable base 23.

[0058] On the other hand, the front and rear wall die means 24 located on the rear wall portion 103 side are receiving means for bending the rear wall portion 103 in the Z direction at the base bending line by contacting the rear wall portion 103 and pushing it in the Z direction as the guide rail 21 rises. Two front and rear wall die means 24L are erected on the fixed base portion 22 located on the rear wall portion 103 side, and two front and rear wall die means 24R are erected on the movable base portion 23.

[0059] The front and rear wall die means 24, which are erected from the movable base 23, can be moved in the X direction on the guide rail 21 by the movable base 23 to match the size of the product PR in the X direction, based on instructions from the control unit 50 (Mx in Figures 2-5).

[0060] The side wall die means 27L, R are receiving means for bending the flaps 105L, R along the fold line at the base. One side wall die means 27L is erected on the fixed base 22 located on the front wall surface 102 side and one side wall die means 27L is erected on the fixed base 22 located on the rear wall surface 103 side. In addition, one side wall die means 27L is erected on the movable base 23 located on the front wall surface 102 side and one side wall die means 27L is erected on the movable base 23 located on the rear wall surface 103 side.

[0061] The side wall die means 27, which is erected from the movable base 23, can be moved in the X direction on the guide rail 21 by the movable base 23 to match the size of the product PR in the X direction, based on instructions from the control unit 50 (Mx in Figures 2-5).

[0062] The inner flap pushing means 25 and 26 are lever members that, when the guide rail 21 rises, come into contact with a pair of abutting inner flaps 107 and 106 and push forward in the Z direction, thereby bending the flaps 107 and 106 in the Z direction at their base bend lines.

[0063] As lever members for folding the flaps 107L and 106L, one inner flap pushing means 26L and 25L are erected on the fixed base 22 located on the front wall surface 102 side and the fixed base 22 located on the rear wall surface 103 side, respectively.

[0064] Furthermore, as lever members for folding flaps 107R and 106R, one inner flap pushing means 26R and 25R are erected on the movable base 23 located on the front wall portion 102 side and the movable base 23 located on the rear wall portion 103 side, respectively.

[0065] The internal flap pushing means 25R and 26R, which are erected from the movable base 23, can be moved in the X direction on the guide rail 21 by the movable base 23 to match the size of the product PR in the X direction, based on instructions from the control unit 50 (Mx in Figures 2-5).

[0066] (Details of the internal flap lifting mechanism 25) As shown in Figures 2(b), 4, and 6, the inner flap lifting means 25L, R includes an inner flap lifting lever 251 that contacts a pair of abutting inner flaps 107L, R (sometimes collectively referred to as "inner flap 107"), a slide arm 252 that holds the inner flap lifting lever 251, a slide mechanism 253 that allows the slide arm 252 to reciprocate in the Z direction, and a support column 254 that holds the slide mechanism 253.

[0067] With this configuration, the internal flap pushing means 25 is configured to adjust the relative height δ (see Figure 4) of the slide arm 252 with respect to the front and rear wall die means 24 by operating the slide mechanism 253 to change the height of the slide arm 252 in the Z direction.

[0068] The above-mentioned operation of folding the pair of butt-joint inner flaps 107L and R is performed together with the movement of the front and rear wall die means 24 in the Z direction, provided that the relative height δ (see Figure 4) of the inner flap pushing means 25 with respect to the front and rear wall die means 24 is greater than or equal to a predetermined value.

[0069] Subsequently, when folding the rear wall portion 103 and the pair of abutting outer flaps 108L and R, the sliding mechanism 252 lowers the slide arm 252 in response to the rise of the guide rail 21, thereby preventing the inner flap push-up lever 251 from rising more than necessary. This allows the absolute height of the inner flap push-up lever 251 to be set to an optimal height.

[0070] Figure 7 is a perspective view showing the production of a half-carton 100H with a longer height dimension by the carton-making device 1, and Figure 8 shows the production of a half-carton 100L with a shorter height dimension. Figure 9 is a perspective view showing the production of a half-carton by a conventional carton-making device.

[0071] In conventional box-making machines, as shown in Figure 9, the inner flap pushing lever 251X in the inner flap pushing mechanism 25X is directly fixed to the support column 254X, and a structure is adopted in which the height of the inner flap pushing lever 251X cannot be changed.

[0072] However, with this structure, when the inner flap push-up lever 251 is brought into full contact with the inner flaps 107L and R to fold the flaps 107, the following problems arose when the half-box cartons 100H, which have a longer height dimension, and the half-box cartons 100L, which have a shorter height dimension, were mixed together as the items to be manufactured.

[0073] In other words, for example, if the height of the inner flap lifting lever 251X is set high to match the half carton 100H, then for the half carton 100L, which has a shorter height dimension, when the front and rear wall die means 24 are pushed up (Mx in Figure 9) and the rear wall portion 103 and the outer flap 108L and R are folded, the inner flap lifting lever 251X comes into contact with the outer flap 108 (part A in the same figure).

[0074] On the other hand, if the height of the inner flap push-up lever 251X is set low to match the shorter height of the half-box carton 100L, then when using the longer height of the half-box carton 100H, the length from the base of the inner flaps 107L and R is long, preventing the inner flap push-up lever 251 from making sufficient contact with the inner flaps 107L and R, resulting in a problem of defective folding of the flaps 107.

[0075] In contrast, the box-making apparatus 1 according to this embodiment has a structure that can restrict the internal flap push-up lever 251 from rising more than necessary, as shown in Figures 7(a) and (b). Therefore, even when half-box cartons 100H with a long height dimension and half-box cartons 100L with a short height dimension are mixed together, the occurrence of the above-mentioned problems can be suppressed.

[0076] Specifically, in the box-making operation for the half-box carton 100H with a long height dimension, the relative height δH of the inner flap-up lever 251 with respect to the front and rear wall die means 24 is set to a predetermined value or higher. Then, the inner flap-up lever 251 moves together with the front and rear wall die means 24 as the guide rail 21 rises, thereby bending the flap 107 in the Z direction.

[0077] In this case, even if the height of the half-box carton 100H is high and the length from the base to the tip of the flap 107 is long, by setting the relative height δH to a predetermined value or higher, the inner flap push-up lever 251 can be brought into sufficient contact with the inner flaps 107L and R, and the flap 107 can be folded upward.

[0078] Subsequently, when the rear wall portion 103 and the outer flaps 108L and R are folded, the sliding mechanism 252 lowers the slide arm 252 as the front and rear wall die means 24 rise (MA in Figure 7), thereby limiting the rise of the inner flap push-up lever 251.

[0079] As a result, when the rear wall portion 103 and the outer flaps 108L and R are folded, the inner flap push-up lever 251 is sufficiently separated from the outer flap 108, and the two do not come into contact.

[0080] On the other hand, in the box-making operation for the shorter half-box carton 100L, as shown in Figure 8, the relative height δL of the inner flap push-up lever 251 with respect to the front and rear wall die means 24 is set to a value smaller than a predetermined value. The inner flap push-up lever 251 then moves together with the front and rear wall die means 24 as the guide rail 21 rises, thereby folding the flap 107 upward.

[0081] In this case, because the relative height δL of the inner flap lifting lever 251 with respect to the front and rear wall die means 24 is low, the inner flap lifting lever 251 is sufficiently separated from the outer flap 108, and the two do not come into contact.

[0082] <Operation of the box-making device 1> Next, the operation of the box-making apparatus 1 will be explained using diagrams.

[0083] First, we will explain the box-making process for the 100H half-box carton, which has a longer height dimension.

[0084] Figures 10-12(a) are left side views illustrating the box-making operation of the box-making device 1 for half-box cartons 100H, and (b) is a front view.

[0085] First, in the initial state, during the box-making operation for the half-box carton 100H with a long height dimension, the relative height δH (see Figure 7) of the inner flap push-up lever 251 with respect to the front and rear wall die means 24 is set to a predetermined value or higher, and the blank sheet 100(H) of the half-box carton 100H is placed on the base 40 by the sheet loading means (not shown) (T1 in Figures 10(a) and (b)).

[0086] Next, the product supply and holding means 10 transports the product PR by sliding it from the product transport table 17 onto the blank sheet 100(H) while surrounded by the rear holding portion 132, the front holding portion 133, and the pair of side holding portions 134 in a plan view, and the product PR is placed on the base surface portion 101 of the blank sheet 100(H) (T2 in Figures 11(a) and 11(b)).

[0087] Next, with the top surface of the product PR held by the product holding means 12 (M1 in Figures 12(a) and (b)), the inner flap pushing means 25 and 26, with their respective Z-direction tip portions 26a and 251a contacting the pair of abutting inner flaps 107 and 106 as the guide rail 21 rises, push forward in the Z direction (upward), thereby bending the flaps 107 and 106 upward in the Z direction at their base fold lines (M2 in the same figure).

[0088] In this case, by setting the relative height δH (see Figure 7) to a half-box carton 100H to be greater than or equal to a predetermined value, the inner flap push-up lever 251 can be brought into sufficient contact with the inner flap 107, and the flap 107 can be folded in the Z direction (upward) without any problems.

[0089] Next, as the front and rear wall die means 24 rises, it contacts the front wall portion 102 or the rear wall portion 103 and pushes forward in the Z direction (upward), bending the front wall portion 102 or the rear wall portion 103 in the Z direction (upward) at the base bending line (M3 in Figures 13(a) and (b)). At the same time, as the front and rear wall die means 24 rises, the inner flap pushing means 25 lowers the slide arm 252 by the operation of the slide mechanism 252 (MA in the same figure), thereby limiting the rise of the inner flap pushing lever 251.

[0090] As a result, when the rear wall portion 103 and the outer flap 108 are folded, the maximum value of the relative height δH (see Figure 7) of the tip 251a of the inner flap push-up lever 251 with respect to the pressing surface (bottom surface) of the product PR is limited to a predetermined value or less, and the tip 251a of the inner flap push-up lever 251 is sufficiently separated from the outer flap 108 (δ1 in the same figure), preventing the two from coming into contact.

[0091] With the above steps completed, the box-making process for the half-box carton 100H is finished.

[0092] Next, we will explain the box-making process for half-box cartons with a shorter height dimension (100L).

[0093] Figure 14(a) is a left side view illustrating the box-making operation for a 100L half-box carton by the box-making device 1, and (b) is a schematic front view.

[0094] First, in the initial state, during the box-making operation for the half-box carton 100L with a shorter height dimension, the relative height δL (see Figure 8) of the inner flap push-up lever 251 with respect to the front and rear wall die means 24 is set to a predetermined value or less. The subsequent operations of placing the blank sheet 100(L) of the half-box carton 100L onto the base 40 and placing the blank sheet 100(L) of the product PR onto the base surface portion 101 by the product supply and holding means 10 are the same as the operations shown in Figures 10(a)(b) and 11(a)(b).

[0095] Next, with the top surface of the product PR held by the product holding means 12 (Figure 14(a)(b)M1), the inner flap pushing means 25 and 26, as the guide rail 21 rises, come into contact with the pair of abutting inner flaps 107 and 106 and push forward in the Z direction (upward), thereby bending the flaps 107 and 106 upward in the Z direction at their base fold lines (M2 in the same figure).

[0096] In this case, although the relative height δL (see Figure 8) is set to a value smaller than a predetermined value, since the box to be manufactured is a half-box carton of 100L, the inner flap push-up lever 251 can be brought into sufficient contact with the inner flap 107, and the flap 107 can be folded in the Z direction without any problems.

[0097] Next, the front and rear wall die means 24, as the guide rail 21 rises, comes into contact with the front wall portion 102 and the rear wall portion 103 and pushes forward in the Z direction (upward), thereby bending the front wall portion 102 and the rear wall portion 103 in the Z direction (upward) at the base bending line (M3 in Figures 15(a) and (b)).

[0098] In this case, the inner flap pushing means 25 does not lower the slide arm 252 by the operation of the slide mechanism 252 as the front and rear wall die means 24 rise, and the upward movement of the inner flap pushing lever 251 is not restricted.

[0099] However, since the relative height δL (see Figure 8) is set to be smaller than a predetermined value to accommodate a half-box carton of 100L, the maximum relative height δL (see Figure 8) of the tip 251a of the inner flap push-up lever 251 with respect to the pressing surface (bottom surface) of the product PR when the rear wall portion 103 and the outer flap 108 are folded is limited to a predetermined value or less. As a result, the tip 251a of the inner flap push-up lever 251 is sufficiently separated from the outer flap 108 (δ1 in the same figure), preventing contact between the two.

[0100] With the above steps completed, the carton manufacturing process for a half-carton of 100L is finished.

[0101] As described above, the box-making apparatus 1 can perform the following operations when making half-box cartons of different height dimensions: a blank sheet 100 is placed on the base 40 by a sheet loading means (not shown), a product PR is placed on and held on the base surface 101 of the blank sheet 100 by a product supply and holding means 10, the product PR is used as a punch member (male), the die mechanism unit 20 is moved in the bending direction relative to the product PR to fold the blank sheet 100 along the folding line to form an open half-box carton A, and the manufactured half-box carton A is discharged by a discharge means (not shown).

[0102] <Summary> As described above, the box-making apparatus 1 according to the embodiment is a box-making apparatus 1 that folds a blank sheet 100 along a folding line to form an open-lid half-box carton 100A, wherein the blank sheet 100 has a front wall portion 102, a base portion 101, a rear wall portion 103, a lid portion 104 along a first direction, a pair of butt-joint inner flaps 107L, R that sandwich the rear wall portion 103 in a second direction perpendicular to the first direction, and a pair that sandwich the lid portion 104 in the second direction The base 40 on which the blank sheet 100 is mounted includes a pair of butt-joint outer flaps 108L, R (sometimes collectively referred to as "outer flap 108"), a punch holding means 12 that holds a punch member PR mounted on the base surface portion 101 of the blank sheet 100, and a punch holding means that, by relative movement relative to the punch member PR in the bending direction (Z direction) opposite to the punch member PR, comes into contact with a pair of butt-joint inner flaps 107L, R and pushes in the bending direction. The device includes an inner flap pushing means 25 that moves forward to bend a pair of butt-joint inner flaps 107L and R in the bending direction at the fold line at their base, and a front and rear wall die means 24 that, by relative movement with respect to the punch member PR in the bending direction, contacts the rear wall portion 103 and pushes forward in the bending direction, bending the pair of butt-joint inner flaps 107L and R, and then bending the rear wall portion 103 and a pair of butt-joint outer flaps 108L and R in the bending direction at the fold line at the base of the rear wall portion 103. The inner flap pushing means 25 is configured to adjust its relative height δ (see Figure 4) with respect to the front and rear wall die means 24, and when the relative height δ is greater than or equal to a predetermined relative height, the maximum relative height of the inner flap pushing means 25 with respect to the pressing surface of the punch member is limited to a predetermined value or less when bending the rear wall portion 103 and a pair of butt-joint outer flaps 108L and R.

[0103] In another embodiment, the inner flap pushing means 25 is configured such that when the relative height δ is greater than or equal to a predetermined relative height and the rear wall portion 103 and a pair of abutting outer flaps 108L, R are bent, the relative height δ decreases as the front and rear wall die means 24 moves relative to the bending direction, thereby limiting the relative movement in the bending direction.

[0104] Conventional box-making machines employ a structure that does not allow for adjustment of the height of the internal flap lifting mechanism.

[0105] Therefore, in cartons with a short height dimension, the butt-joint inner flap lifting mechanism extending from the rear wall to both sides in the width direction comes into contact with the butt-joint outer flaps extending from the lid to both sides in the width direction, causing snagging and resulting in damage to the packaging box during manufacturing. To avoid this, it was necessary to set the height of the inner flap lifting mechanism low.

[0106] However, in this case, a problem arises: the inner flap of a carton with a long height cannot be folded in sufficiently.

[0107] Therefore, depending on the height of the carton, it was necessary to use internal flap lifting mechanisms of different heights, which resulted in increased workload due to the need for changes and reduced production efficiency.

[0108] In contrast, the box-making apparatus 1 described above adjusts the relative height δ to match the height of the half-box carton 100A to be made, and simultaneously with the folding of the front wall portion 102 or the rear wall portion 103 of the half-box carton 100H, the inner flap pushing means 25 lowers the slide arm 252 in conjunction with the rise of the front and rear wall die means 24, thereby limiting the rise of the inner flap pushing lever 251.

[0109] As a result, when the rear wall portion 103 and the outer flap 108 are folded, the maximum relative height δ of the tip 251a of the inner flap push-up lever 251 with respect to the pressing surface (bottom surface) of the product PR is limited to a predetermined value or less, and the tip 251a of the inner flap push-up lever 251 is sufficiently separated from the outer flap 108, preventing contact between the two.

[0110] As described above, the box-making apparatus allows for the smooth operation of forming an open-lid half-carton A by using the product PR as a punching member (male die) and moving the die mechanism unit 20 in the bending direction relative to the product PR, regardless of the height dimension of the half-carton 100 to be made. As a result, it is possible to provide a box-making apparatus and method that enables the making of cartons with different height dimensions without changing the inner flap lifting means, and that suppresses damage to the packaging box during box making.

[0111] ≪Variations≫ Although a box-making apparatus according to an embodiment has been described, this disclosure excludes its essential characteristic components. The present invention is not limited in any way to the embodiments described above. For example, forms obtained by applying various modifications to the embodiments that a person skilled in the art could conceive of, and forms realized by arbitrarily combining the components and functions of each embodiment without departing from the spirit of the present invention are also included in this disclosure. Below, a modified example of such a form will be described.

[0112] (1) In the box-making apparatus 1 according to the above embodiment, during the box-making operation, the front and rear wall die means 24 comes into contact with the front wall portion 102 and the rear wall portion 103 as the guide rail 21 rises and pushes forward in the Z direction, thereby bending the front wall portion 102 and the rear wall portion 103 in the Z direction at the bending line at the base.

[0113] However, in the box-making operation, the die mechanism unit 20 moves relative to the product PR, which corresponds to the punch member (male die), during box-making, and folds the blank sheet 100 along the folding line to form a half-box carton A. For example, the punch member (male die) may move in a direction relative to the die mechanism unit 20 to form a half-box carton A.

[0114] (2) In the box-making apparatus 1 according to the above embodiment, the product PR is used as the punching member (male mold) to perform the box-making operation. However, the punching member may also be configured to use a male mold mechanism using a mandrel instead of the product PR.

[0115] (3) In the box-making apparatus 1 according to the above embodiment, the folding operation for box making was described as being performed sequentially in two parts, operation M2 and operation M3, but it is not limited to this. Depending on the state of the half-box carton 100A, box making may be completed by pressing both simultaneously or by pressing only one of them, so the appropriate method should be selected.

[0116] ≪Additional Information≫ The embodiments described above all represent preferred specific examples of the present invention. The numerical values, shapes, materials, components, arrangement and connection configurations of components, processes, and order of processes shown in the embodiments are examples only and are not intended to limit the present invention. Furthermore, components in the embodiments that are not described in the independent claims representing the highest-level concept of the present invention are described as any components that constitute a more preferred form.

[0117] Furthermore, the order in which the above methods are performed is illustrative for the purpose of specifically illustrating the present invention, and may be performed in a different order. Also, some of the above methods may be performed simultaneously (in parallel) with other methods.

[0118] Furthermore, for the sake of easier understanding of the invention, the scale of the components shown in the figures of each embodiment described above may differ from that of the actual components. Moreover, the present invention is not limited by the descriptions of each embodiment described above, and can be modified as appropriate without departing from the spirit of the invention.

[0119] Furthermore, at least some of the functions of each embodiment and its modified form may be combined. [Industrial applicability]

[0120] A box-making apparatus according to one aspect of this disclosure can be used as a box-making apparatus in a manufacturing line or the like to make packaging boxes for products, parts, workpieces, packaging, various containers, etc. It can also be suitably used as a box-making apparatus in various logistics operations to make boxes for cargo and packaging. [Explanation of symbols]

[0121] 1 Box making equipment 10 Product supply holding means 11 Workhead 12 Product holding means 121 Additional holding part 122 Basic holding part 13 Product supply means 131 Position-adjustable mechanism 132 Back holding part 133 Front holding part 124 Side holding part 14 Robot Arm 15 Robot Arm 16. Robot body base 17 Product transport tables 20 Die mechanism unit 21 Guide rails 22 Fixed base 23 Movable base 24 Front and rear wall die means 25 Internal flap lifting means 251 Inner flap push-up lever 252 Slide Arm 252 Slide mechanism 253 Post 26 Inner flap lifting means 27 Side wall die means 40 bases 50 Control Unit 100 Blank Sheets 100A Half Box Carton 100H Tall Carton 100L Low-profile carton PR Product (Punching Material)

Claims

1. A box-making apparatus that folds a blank sheet along a folding line to form an open-lid half-box carton, The blank sheet includes a front wall portion, a base portion, a rear wall portion, and a lid portion along a first direction, a pair of butt-joint inner flaps sandwiching the rear wall portion in a second direction perpendicular to the first direction, and a pair of butt-joint outer flaps sandwiching the lid portion in the second direction. The base on which the blank sheet is placed, A punch holding means for holding a punch member placed on the base surface of the blank sheet, An inner flap pushing means that, by relative movement relative to the punch member in the bending direction opposite to the punch member, comes into contact with the pair of butt inner flaps and pushes forward in the bending direction, thereby bending the pair of butt inner flaps in the bending direction at the base bending line, The die means, by relative movement of the punch member in the bending direction, contacts the rear wall surface and pushes forward in the bending direction, thereby bending the pair of butt inner flaps, and then bending the rear wall surface and the pair of butt outer flaps in the bending direction at the bending line at the base of the rear wall surface, The internal flap pushing means is configured to be able to adjust its relative height to the die means. When the aforementioned relative height is greater than or equal to a predetermined relative height, when the rear wall portion and the pair of butt-joint outer flaps are bent, the relative height of the inner flap lifting means with respect to the pressing surface of the punch member is limited to a predetermined value or less. Box making equipment.

2. The inner flap pushing means, when the relative height is greater than or equal to a predetermined relative height and when bending the rear wall portion and the pair of abutting outer flaps, reduces the relative height as the die means moves relative to the bending direction, thereby limiting the relative movement in the bending direction. The box-making apparatus according to claim 1.

3. A method for making a box by folding a blank sheet along a folding line to form an open-lid half-box carton, The blank sheet includes a front wall portion, a base portion, a rear wall portion, and a lid portion along a first direction, a pair of butt-joint inner flaps sandwiching the rear wall portion in a second direction perpendicular to the first direction, and a pair of butt-joint outer flaps sandwiching the lid portion in the second direction. The process of placing the blank sheet onto the base, A step of holding the punch member placed on the base surface of the blank sheet, The process involves moving the inner flap pushing means relative to the punch member in the bending direction opposite to the punch member, bringing it into contact with the pair of abutted inner flaps, and pushing it forward in the bending direction, thereby bending the pair of abutted inner flaps in the bending direction at the base fold line, The die means is moved relative to the punch member in the bending direction, so that it contacts the rear wall and pushes forward in the bending direction, thereby bending the rear wall and the pair of butt outer flaps in the bending direction at the bending line at the base of the rear wall, after the pair of butt inner flaps have been bent. The internal flap pushing means is configured to be able to adjust its relative height to the die means. When the aforementioned relative height is greater than or equal to a predetermined relative height, in the process of bending the rear wall portion and the pair of butt-joint outer flaps, the relative height of the inner flap pushing means with respect to the pressing surface of the punch member is limited to a predetermined value or less. Box manufacturing method.

4. When the relative height of the inner flap lifting means is greater than or equal to a predetermined relative height, in the process of bending the rear wall portion and the pair of abutting outer flaps, the inner flap lifting means reduces the relative height as the die means moves relative to the bending direction, thereby limiting the relative movement in the bending direction. The method for manufacturing a box according to claim 3.

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