Case erector apparatus and method for erecting left-handed or right-handed cases

Abstract

Provided herein is a case erector apparatus suitable for erecting right-handed and left-handed cases. The case erector apparatus has a blank grabber arm including a blank grip and having an extension in a case conveying direction along a case conveying axis between first and second opposing ends, the blank grabber arm adapted to be translatable along a blank opening axis from a start position to a collection position, a moveable pusher arm including a folding blade and a case grip and having a length on the blank opening axis between upper and lower ends, and a fixed erection unit that includes a retractable stop plate, a case support, and a pair of fixed folding blades that are arranged in parallel and spaced a distance apart from each other on a case height axis. A method for erecting right-handed or left-handed cases is also provided.

Description

Case Erector Apparatus and Method for Erecting Left-Handed or Right-Handed CasesField of the invention

[0001] The present disclosure generally relates to apparatus for handling boxes, cartons, cases, and like packaging suitable for containing product, and particularly, to a case erector apparatus, which is configured to be able to erect both right-handed and left-handed cases from one or more blanks, in a combined, standalone module. In particular, the case erector apparatus described herein is configured with respective settings for both left-handed and right-handed cases and is designed such that operation of the case erector apparatus can be readily switched between lefthanded and right-handed cases with relative ease and speed. A related method for erecting right- handed or left-handed cases is further provided herein.Background

[0002] Packaging systems are an important part of manufacturing processes. Particular aspects such as erecting a blank into a fully formed case, packing the case with product, and sealing the product-loaded case may often account for significant time and / or expense associated with these systems. Historically, manual human labor has been used to performed these tasks of assembling, packing, and sealing the cases. However, there has been a shift in recent times toward the development of automated systems to perform these tasks.

[0003] Such automated systems may generally include one or more mechanisms for erecting, filing, and sealing cases. In particular, mechanisms for erecting cases, often referred to as case erectors, are the machines that automatically assemble a case from a blank. In typical operation, a case erector takes a blank from a supply or source of blanks, such as a stack or magazine of blanks, and effectuates unfolding of the selected blank. Once or even while the selected blank is unfolded, one or more of flap folding, tucking, and sealing may be performed in furtherance of forming the fully erected case.

[0004] The blanks from which the cases are formed can be formed in a variety of configurations. One standard configuration is that of a regular slotted container (RSC). An RSC is a case which has four flaps that make up the bottom of the case and another four flaps that make up the top of the case. Each of the top flap and bottom flap sets include a pair of opposing minor flaps alternating with a pair of opposing major flaps. The remainder of the RSC includes four panels, which for an exemplary rectangular case, include a pair of opposing major panels and a pair of opposing minor panels. Depending on the order in which the panels / flaps are arranged in broken-down form, the RSC case is either a right-handed case or a left-handed case. For a right-handed case, the minor panel is arranged on the right side of the major panel when case graphics on the major panel are oriented right side up, and conversely, for a left-handed case, the minor panel is arranged on the left side of the major panel when case graphics on the major panel are oriented right side up.

[0005] Because of this difference in the arrangement of the major and minor cases faces, the direction in which left-handed cases are assembled is different from the direction in which right- handed cases are assembled. Left-handed cases are assembled from the left side to the right while right-handed cases are assembled from the right side to the left. This essentially means that toaccount for these difference, a right-handed case erector is required to erect a right-handed case and a left-handed case erector is required to erect a left-handed case. Known solutions thus involve case erectors that are either configured for only one type of case, left-handed or right-handed, but not both; or those that require some physical adaptation(s), such as the exchange of one or more parts, to switch between left-handed and right-handed cases.

[0006] The first type of solution, case erectors that are configured for only one type of case, are disadvantageous because they lack versatility. Right-handed case erectors can only erect right- handed cases and left-handed case erectors can only erect left-handed cases, and. Moreover, these single direction case erector impose constraints on the manufacturing line, particularly downstream of the case erector, because the other mechanisms, like the packing and / or sealing machines, are also configured for the same type of case. Thus, two mirror-image manufacturing lines would be required in order to be able to manufacture both left-handed and right-handed cases, and by extension, means higher costs and essentially twice the space is needed to accommodate two sets of manufacturing equipment.

[0007] The second type of solution, case erectors to which some physical adaptation^) is / are made to switch production between left-handed and right-handed cases, also suffer from disadvantages. These solutions require the exchange of parts which is sub-optimal because this often requires the entire manufacturing line to be shut down to adapt the machinery for the other type of case. In addition to the downtime, adaptation of the machinery may need to be performed by a specialized mechanic. Additional floor and / or storage space and internal tracking of the changeover part(s) may also be needed.

[0008] Despite efforts made to automate the tasks of assembling, packing, and sealing cases in packaging systems, there still remains a need for further improvements to the existing automated systems, and particularly with respect to case assembly. More specifically, there remains a need for case erector modules with increased versatility in terms of processing both left-handed and right- handed type cases and which are enabled to be readily switched between configurations with relative speed and ease, with little to no downtime of the manufacturing line and / or at minimal expense.Summary

[0009] It has been found that despite prior art solutions for automating the tasks of assembling, packing, and sealing of cases, there is still a need to improve existing automated systems, particularly in relation to the assembly of cases. In this regard, it is important that the versatility of these automated systems, and especially case erectors modules, be increased.

[0010] An objective of the present disclosure is thus to provide a case erector apparatus with increased versatility that is enabled to readily switch between processing and left-handed and right- handed type cases with relative speed and ease. Further, it is desirable that the switching between left-handed and right-handed cases may be performed with little to no downtime of the manufacturing line and / or at minimal expense.

[0011] Objectives set forth herein are achieved by the present case erector apparatus as defined in the appended claims.

[0012] Accordingly, in a first aspect of the disclosure, there is provided a case erector apparatus having a blank grabber arm comprising a blank grip and having an extension in a case conveying direction along a case conveying axis of the case erector apparatus between first and second opposing ends, the blank grabber arm adapted to be translatable in a blank opening direction along a blank opening axis of the case erector apparatus from a start position to a collection position, a moveable pusher arm having a length in the blank opening direction between upper and lower ends, the pusher arm comprising a folding blade and a case grip, and a fixed erection unit comprising a retractable stop plate, a case support, and a pair of fixed folding blades that are arranged in parallel and spaced a distance apart from each other on a case height axis.

[0013] By providing the case erector apparatus with both a folding blade and a pair of fixed folding blades, both left-handed and right-handed cases can be erected by an independent erector module. Either type of case can be simply erected by bringing a selected blank, depending on the type of case, into contact with one of either the folding blade for right-handed cases or the pair of fixed folding blades for left-handed cases, while the selected blank is grabbed and raised in the longitudinal direction by the blank grabber arm.

[0014] In non-limiting exemplary embodiments, the case erector apparatus may further comprise a base frame which comprises a conveyor and a stop element.

[0015] The base frame may also comprise a lift that is adapted to be translatable along the blank opening axis from a load position to a collection position. From an automation standpoint, the provision of a lift may provide further versatility to the case erector apparatus, particularly when a stack of blanks are arranged on the base frame. Each time a blank is removed from the stack, the remaining blanks may be automatically raised by the lift such that the top blank is arranged at the collection point, ready for collection by the blank grabber arm.

[0016] In certain embodiments, the lift may comprise a blank detector which is configured to detect when at least one blank is in the lift. In some non-limiting embodiments, it may be preferable that the blank detector comprises a capacitive switch. Of course, it is contemplated that other sensors and / or mechanisms suitable to detect one or more blanks may be readily substituted and / or additionally provided in the case erector apparatus by one or ordinary skill in the field.

[0017] The lift may comprise a lift grip. The lift grip may be configured to hold a bottom blank from a stack of a plurality of blanks arranged in the lift in contact with the conveyor. In other words, the lift grip may prevent the bottom blank from a stack of blanks from moving while the penultimate blank from the stack is picked up by the blank grabber arm. In certain embodiments, the lift grip preferably comprises a vacuum cup. Further, lift grip and / or the vacuum cup may comprise a suction cup. It is to be understood that a vacuum cup is but one example, and it is further envisioned that one or more other known gripping elements can readily be provided, additionally or alternatively, on or as the lift grip, as desired.

[0018] The lift may further comprise an actuator. In non-limiting exemplary embodiments, the actuator may be a servomotor. However, it is to be understood that other actuators can be readily incorporated into the lift in place of or in addition to the servomotor by one of ordinary skill.

[0019] The lift may comprise a position sensor. In certain non-limiting embodiments, the position sensor it may be preferable to arrange the position sensor on the stop element. Having a position sensor arranged on the stop element may further ensure that the one or more blanks are correctly positioned, particularly at the collection position for ease of collection by the blank grabber arm.

[0020] The stop element may comprise a transverse base member and a plurality of prongs extending a length therefrom. Each prong is spaced a distance apart from any adjacent prong the transverse based member.

[0021] The stop element is adapted to be moveable along the case conveying axis. By making the stop element moveable along the case conveying axis, this permits the positioning of the stop element to be adjusted to accommodate both left-handed and right-handed case blanks on the base frame. Thus in certain non-limiting embodiments, it is preferred that the stop element is moveable along the case conveying axis between a left-handed case position and a right-handed case position.

[0022] In certain non-limiting embodiments, the blank grip may comprise at least one vacuum cup. To this effect, it is contemplated that the blank grip may comprise a single vacuum cup, or in the alternative, the blank grip may comprise a plurality of vacuum cups. For example, in one non-limiting embodiment, the blank grip may comprise two vacuum cups, and in another non-limiting embodiment, the blank grip may comprise four vacuum cups. It is to be understood that the number of the vacuum cups which the blank grip may comprise may be selected, for example, based on one or more of the size of the case(s) being erected, the shape of the case(s) being erected, the size of the vacuum cup(s), the shape of the vacuum cup(s), and the type of the vacuum cup(s), and as such, may be readily selected, as desired, by the ordinarily skilled artisan.

[0023] In certain embodiments, the blank grip is typically arranged to hold a blank on a major case face thereof. Further, the blank is preferably held at a position adjacent to a folding edge between the major case face and a minor case face. Having the blank grip positioned as close to the folding edge of the blank as possible may reduce, if not all together avoid, the risk that a selected blank is dislodged or peeled away from the blank grip during assembly of the blank into an erected case. Depending on the type of blanks, i.e. right-handed or left-handed cases, the folding edge may be a leading folding edge or a trailing folding edge.

[0024] In one non-limiting example, the blank grabber arm may further comprise a step motor. The provision of a step motor may facilitate actuation and / or translation of the blank grabber arm. However, it is to be understood that a step motor is merely exemplary and other solutions known in the field may be readily substituted in place of or in addition to the blank grabber arm by one of skill.

[0025] The folding blade is arranged at the lower end of the moveable pusher arm, and the case grip is arranged above the folding blade. For right-handed cases, this arrangement allows the folding blade to be brought into contact with a minor case face of a right-handed case. This facilitates unfolding and squaring of the blank into an erected right-handed case. For left-handedcases, having the case grip arranged above the folding blade in the blank opening direction enables the pusher arm to easily grip an unfolded / erected left-handed case. This facilitates the pusher arm to further convey the erected left-handed case in the conveying direction toward a transfer conveyor arranged behind the fixed erection unit for discharge from the case erector apparatus.

[0026] The folding blade comprises a straight segment and an arcuate segment. The arcuate segment is arranged to come into contact with a minor case face of a right-handed case. Contact with a case face is preferably direct, but may, in certain embodiments, be indirect if desired. The straight segment may be arranged at the lower end of the pusher arm to extend a distance from the pusher arm in the case conveying direction. This creates a small ledge or shelf at the end of the pusher arm which may provide additional support with gripping and / or holding an erected case by the pusher arm. Additionally or alternatively, the arcuate segment facilitates relatively smooth contact between the folding blade and a case face of a blank. This may further minimize, if not avoid, the chance of damage to the blank during unfolded and / or assembly into an erected lefthanded or right-handed case.

[0027] The case grip comprises a plurality of vacuum cups. Having a plurality of vacuum cups assists to keep a left-handed case perpendicular so that it does not revert back into a folded or semi-folded configuration. In certain non-limiting embodiments, the case grip may comprise four vacuum cups. However, it is to be understood that number of vacuum cups may be readily selected by the ordinarily skilled artisan, as desired.

[0028] Similar to the folding blade, each fixed folding blade comprises a straight segment and an arcuate segment. The arcuate segment is arranged to contact a minor case face of a left-handed case. Contact with a case face is preferably direct, but may, in certain embodiments, be indirect if desired. Likewise, the arcuate segments facilitate relatively smooth contact between the fixed folding blades and a case face of a blank. This may further minimize, if not avoid, the chance of damage to the blank during unfolded and / or assembly into an erected case.

[0029] The case erector apparatus may, in certain exemplary embodiments, comprise an alignment member that is adapted to align one or more blanks in a load position. The alignment member may comprise at least one case length stop element and at least one case height stop element. Having the one or more blanks appropriately aligned in the case conveying direction and on a case height axis may ensure that the one or more blanks are not displaced during assembly, and by extension, further ensure that the chance that one or more blanks are erected improperly or with defects is reduced, if not all together avoided.

[0030] The alignment member may also, in certain embodiments, comprise a moveable alignment arm having a free end arranged on a case-contacting side of the alignment member, the free end comprising the case length stop element. The alignment arm is adapted to be translatable in the case conveying direction, which allows the case length stop element to be arranged at different positions on the case conveying axis. This facilitates alignment not only of different sized cases but also both left-handed and right-handed cases in the case conveying direction which are arranged at different positions on the base frame.

[0031] In one non-limiting embodiment, the alignment member may further comprise a step motor. However, it is to be understood that other known mechanisms can be readily incorporated into the alignment member in place of or in addition to the step motor by one of ordinary skill.

[0032] Additionally, the alignment member may further comprise an encoder, in certain embodiments. This can assist to further ensure correct positioning of the alignment member.

[0033] In another aspect of the present disclosure, a method for erecting right-handed or lefthanded cases is provided. The method comprises providing a case erector apparatus as described herein, loading one or more blanks, aligning the one or more blanks in a load position for either right-handed cases or left-handed cases, and actuating the blank grabber arm to select a top blank from the one or more blanks. The selected blank unfolds while being raised by the blank grabber arm. When the one or more blanks are right-handed cases, the method further comprises bringing the pusher arm into contact with a minor case face of the selected blank to square the folding edge such that the selected blank is erected as a right-handed case, and moving the pusher arm in the conveying direction to discharge the erected right-handed case onto a transfer conveyor. In the alternative when the one or more blanks are left-handed cases, the method further comprises bringing the minor case face of the selected blank into contact with the pair of fixed folding blades to square the folding edge such that the selected blank is erected as a left-handed case, holding the squared folding edge in place with the retractable stop plate, moving the pusher arm in the conveying direction and gripping the erected left-handed case with the case grip, retracting the stop plate, and moving the pusher arm in the conveying direction to discharge the erected left-handed case onto a transfer conveyor.

[0034] In certain embodiments, the method may further comprise translating the one or more blanks aligned in the load position to the collection position.

[0035] Translating of the one or more blanks from the load position to the collection position may, in non-limiting exemplary embodiments, comprise incrementally raising a lift of the case erector apparatus such that the top blank from the one or more blanks is arranged at the collection position.

[0036] Further objectives, features and advantages of the present absorbent article are described in the detailed description below with reference to the appended drawings.Brief description of the drawings

[0037] The present invention will be discussed in more detail below, with reference to the attached drawings, in which:

[0038] Figure 1 shows an exemplary case erector module according to the present disclosure;

[0039] Figure 2 shows an embodiment of an exemplary base frame;

[0040] Figure 3 shows an exemplary alignment member;

[0041] Figures 4 and 5 each show an embodiment of an exemplary blank grabber arm in relation to a right-handed exemplary blank;

[0042] Figure 6 shows an exemplary pusher arm and exemplary fixed erection unit supporting an erected case;

[0043] Figure 7 shows an exemplary fixed erection unit;

[0044] Figure 8 shows a top view of an exemplary right-handed case aligned by an exemplary alignment member;

[0045] Figure 9 shows a perspective view of an exemplary right-handed case aligned by an exemplary alignment member;

[0046] Figure 10 shows a top view of an exemplary left-handed case aligned by an exemplary alignment member;

[0047] Figure 11 shows a perspective view of an exemplary left-handed case aligned by an exemplary alignment member;

[0048] Figures 12 and 13 show a side view and a perspective view, respectively, of an exemplary right-handed case being erected;

[0049] Figures 14 and 15 show a side view and a perspective view, respectively of an exemplary left-handed case being erected; and

[0050] Figure 16 shows an example arrangement of an exemplary pusher arm and exemplary fixed erection unit with a vertically-oriented stack of blanks.Detailed description

[0051] As a general reference, more than one term may be used to refer to the same axis, reference conventions and / or coordination systems of the case erector apparatus described herein. For example, the terms transverse direction and conveying direction may be used interchangeably herein to refer to the x-axis; the terms longitudinal direction and y-direction may be used interchangeably herein to refer to the y-axis; and likewise, the terms width direction and z-direction may both be used herein to refer to the z-axis.

[0052] Additionally or alternatively, directionality and / or axes of the case erector apparatus may be expressed or described herein relative to an exemplary blank / case. This nomenclature is provided to describe structural elements of the case erector apparatus without limitation to a specific orientation (e.g. horizontal or vertical) of a blank / case relative to the case erector apparatus. For example, the terms case conveying direction and / or case conveying axis are used herein to refer to the direction in which the blank-to-be-erected / case is conveying; further, for a horizontally arranged blank, the case conveying direction may therefore refer to a transverse direction or x-axis of the case erector apparatus. Similarly, the terms blank opening direction and blank opening axis may refer to the direction in which the blank is opened or unfolded; for a vertically arranged blank, the blank opening direction may refer to a z-direction or z-axis of the case erector apparatus, whereas for a horizontally arranged blank, the blank opening direction may refer to a longitudinal direction or y-axis of the case erector apparatus. An exemplary case erector apparatus in accordance with the present disclosure is shown in Figure 1. The case erector apparatus 1 generally includes a base frame 20, an optional lift 30, a blank grabber arm 40, a moveable pusher arm 50, and a fixed erection unit 60. The base frame has an extension along a transverse axis (X) of the case erector apparatus between first and second opposing ends 200a, 200b and comprises a conveyor 201 and a stop element 202. In this non-limiting example, the optional lift is arranged at one of the opposing ends of the base frame in the case conveying direction (x) along the transverseaxis (X) and is adapted to be translatable along in a longitudinal direction (y) along a longitudinal axis (Y) of the case erector apparatus. The blank grabber arm 40 has an extension along the transverse axis (X) between first and second opposing ends 400a, 400b. As can be seen in Fig. 1 , the blank grabber arm is arranged generally above the base frame in the longitudinal direction (y) and generally in parallel with the base frame on the transverse axis (X). The blank grabber arm is also adapted to be translatable in the longitudinal direction (y) along the longitudinal axis (Y). The pusher arm 50 has a length in the longitudinal direction (y) between upper and lower ends 500a, 500b and is adapted to be moveable along the transverse axis (X). As can also be seen in Fig. 1 , the fixed erection unit 60 is arranged generally above the base frame in the longitudinal direction (y) and generally in parallel with the lower end of the moveable pusher arm.

[0053] Fig. 2 depicts an exemplary base frame 20 similar to the base frame of the example case erector apparatus shown in Fig. 1. Here, the exemplary base frame has an extension in the conveying direction (x) between first and second opposing ends 200a, 200b. The base frame also comprises a conveyor 201 and a stop element 202, each of which is generally arranged on one of the opposing ends. In this non-limiting example, the conveyor is generally arranged on the first end and the stop element is generally arranged on the second end. As can be seen in Fig. 2, the stop element is arranged in a portion of the base frame between the second end edge 203 and the last roller 201x of the conveyor in the conveying direction (x). Typically, the stop element is arranged perpendicular to the base frame and / or the conveyor; however, it is contemplated that the stop element may be arranged in a non-perpendicular relationship with either or both of the base frame and conveyor in other non-limiting embodiments. The stop element is adapted to be moveable along the transverse axis (X) in this portion of the base frame between the second end edge and the last roller. Having the stop element moveable in this manner permits both left-handed and right-handed cases to be appropriately positioned on the base frame for subsequent erection once collected by the blank grabber arm. The positioning, and more specifically the alignment of, left-handed and right-handed blanks on the base frame in relation to the stop element will be discussed in further detail below.

[0054] In this non-limiting embodiment, the base frame further comprises a lift 30. Here, the lift is arranged at the second edge 203 and perpendicular or essentially perpendicular to the base frame. The lift is adapted to be translatable along the longitudinal axis (Y). More specifically, the lift is translatable between a load position and a collection position. In exemplary, non-limiting embodiments, the load position corresponds with the lowest point on the longitudinal axis (Y) at which the lift may be arranged. This load position also generally corresponds with the position on the longitudinal axis (Y) at which the base frame can be loaded with a maximum number of blanks for a given magazine or stack of blanks. On the other hand, the collection position generally corresponds with the highest point on the longitudinal axis (Y) at which the lift may be arranged. This collection position is where the top blank from a supply of one or more blanks arranged in the lift is picked up by the blank grabber arm. By providing a lift in this manner, unnecessary long strokes of the blank grabber arm can be avoided, and by extension, the processing time of the blank(s) can be improved.

[0055] Additionally, the lift may be adapted such that each time a blank is collected from the collection position, the lift is incrementally raised such that the top blank from the stack of a plurality of blanks arranged in the lift is arranged at the collection position. The lift may, therefore, be equipped with an actuator, such as a servomotor, to facilitate translation of the lift in the longitudinal direction (y). However, it is to be understood that a servomotor is merely exemplary and other types of actuators and / or mechanisms suitable for raising and lowering the lift may be readily substituted, as desired, in the embodiments of the case erector apparatus described herein.

[0056] The lift may be further equipped with one or more additional elements. For example, the lift may further comprise one or more sensors, including but not limited to, blank detectors and position sensors. In certain non-limiting embodiments, the lift may be provided with at least one blank detector to detect when at least one blank is in the lift. Additionally or alternatively, information from the blank detector may be used to inform actuation of the lift in either direction along the longitudinal axis (Y). In any case, the blank detector may preferably comprise a capacitive switch; but again, it is to be understood that a capacitive switch is merely an exemplary form of a blank detector and other types of detectors and / or mechanisms suitable to detect when at least one blank is in the lift may be readily substituted, as desired by one of skill in the field, in the embodiments of the case erector apparatus described herein.

[0057] In certain embodiments, the lift may also comprise a lift grip (not shown) which is preferably configured to hold a bottom blank from a stack of a plurality of blanks arranged in the lift in contact with the conveyor. The provision of a lift grip helps to minimize, if not all together avoid, the chance of one of more blanks from the plurality of blanks arranged in the lift being displaced during operation of the case erector. This may be especially illustrated in situations in which there are relatively few blanks (e.g., four or less) remaining from a stack in the lift. Further, the lift grip may preferably comprise a vacuum cup. It is contemplated, however, that a vacuum cup is merely one exemplary embodiment, and other types of grips may be readily added to or substituted for the vacuum cup, by one of ordinary skill in the art.

[0058] In certain embodiments, the case erector apparatus may further comprise an optional alignment member that is adapted to align one or more blanks in an xz-plane of the case erector apparatus. An exemplary alignment member is illustrated in Fig. 3. The alignment member 70 has an extension along the transverse axis (X) between first and second opposing ends 700a, 700b. A moveable alignment arm 71 is arranged on the second opposing end. The alignment arm is generally positioned perpendicular to the alignment member and with a free end arranged on a case-contacting side of the alignment member. The free end comprises an x-axis stop element 710, which is configured to contact one or more blanks arranged on the base frame. The alignment arm is also adapted to be translatable along the transverse axis (X). This allows the alignment arm, and particularly the x-axis stop element thereon, to be positioned at different points along the alignment member, which facilitates the alignment of different sized cases for both left-handed and right- handed case types on the base frame in the transverse direction (x).

[0059] The alignment member further comprises first and second z-axis stop elements 702, 703, which each have a respective extension in the z-direction. The first and second z-axis stop elementsare generally positioned perpendicular to the alignment member on the case-contacting side thereof, in parallel with the alignment arm, and spaced a distance apart from each other in the transverse direction (x). As is shown in Fig. 3, the first z-axis stop element is arranged proximal to the first end of the alignment member, and the second z-axis stop element is arranged at or around the center of the alignment member; it is to be understood, however, that this arrangement is exemplary and for illustrative purposes, and the position and / or arrangement of one or both z-axis stop elements may be readily adjusted as desired by one of ordinary skill.

[0060] In operation, one or both z-axis stop elements is / are used to align one or more blanks arranged on the base frame in the z-direction depending on the type of case being constructed, i.e. whether the case(s) is / are right-handed or left-handed case(s). Additionally, the alignment member pushes the blank toward an adjustable back plate 72, shown in Fig. 1 . This plate helps to keep the blank in position, particularly while the lower flaps (case bottom) are being folded. The adjustable back plate may also be arranged so as to absorb the bending force(s) from folding of the lower flaps. Alignment of exemplary left-handed and right-handed cases to this effect will be discussed in further detail hereafter.

[0061] Figs. 4 and 5 depict exemplary blank grabber arms in relation to different sized blanks. A relatively large sized sample blank 9 is shown in Fig. 4. The blank has a major case face 901 and a minor case face 902, which in this non-limiting example, are arranged side by side in a horizontal configuration. In order to be able to pick up the blank, the blank grabber arm is provided with a blank grip, which may comprise a plurality of gripping elements, as shown in Fig. 4. To accommodate the larger sized blank, the plurality of gripping elements may be divided into a plurality of subsets 401 a, 40b, each of which is arranged to grip the blank at a different location. It is preferable that one subset of the gripping elements is arranged adjacent to a leading folding edge 903 of the major case face while another subset is arranged adjacent to a trailing folding edge 904 between the major and minor case faces. These folding edges are typically where the most force is exerted during unfolding of the blank. Forthe larger sized blanks, the subsets of gripping elements are typically spaced some distance apart from each other in the transverse direction (x) and / or in the width direction (z).

[0062] A relatively small sized sample blank 9 is shown in Fig. 5 as another non-limiting example. Like the sample blank of Fig. 4, the relatively small sized blank has a major case face 901 and a minor case face 902, which are arranged side by side in a horizontal configuration. Also, the blank grabber arm is provided with a blank grip 401 that comprises a plurality of gripping elements, which may be divided into a plurality of subsets. However, due to the relatively smaller size of the blank, even when the plurality of gripping elements are divided in a plurality of subsets, the subsets are arranged in relatively close proximity to one another. This may give the appearance that the plurality of gripping elements comprises a single set rather than a plurality of subsets. In any case, it is preferable that one or more gripping elements are arranged adjacent to the leading folding edge 903 of the major case face and that one or more gripping elements are arranged adjacent to the trailing folding edge 904 between the major and minor case faces, as these are the locations where the most force is typically exerted during unfolding of the blank.

[0063] A sample case held by an exemplary blank grabber arm 40 having an extension in the transverse direction (x) between first and second ends 400a, 400b, and generally supported between an exemplary pusher arm and an exemplary fixed erection unit is depicted in Fig. 6. The pusher arm 50 has a length in the longitudinal direction (y) between upper and lower ends 500a, 500b. A folding blade 501 is arranged at the lower end. The folding blade comprises a straight segment 502 and an arcuate segment 503. As can be seen in Fig. 6, the straight segment is connected to the bottom of the lower end and extends a distance out from the pusher arm in the transverse direction (x). This extension of the straight segment forms a relatively short shelf or ledge portion, which as illustrated in Fig. 6, may support a corner of an erected case. The arcuate segment is connected to straight segment and is arranged so as to curve downward in a clockwise (cw) direction therefrom. Further, the arcuate segment preferably has a length that corresponds to approximately one-quarter of a circle or about 90 degrees.

[0064] The pusher arm also comprises a case grip 504, which is arranged above the folding blade. It is preferable, in certain embodiments, that the case grip comprises a plurality of gripping elements. In Fig. 6, for example, the exemplary case grip comprises four vacuum cups. Of course, it is contemplated that other gripping elements suitable to grip an at least partially or fully assembled case may be readily incorporated into or as the case grip, either in place of or in addition to a plurality of vacuum cups, by one of ordinary skill in the art. Turning back to Fig. 6, the vacuum cups are arranged above the folding blade in a single row oriented in the longitudinal direction (y), each vacuum cup spaced a respective distance apart from any adjacent vacuum cup. By way of this arrangement, an erected case may be temporarily ‘gripped’ with relative ease by the pusher arm, which further facilitates conveyance of the erected case toward a transfer conveyor where it is subsequently discharged from the case erector apparatus. Additional advantages of this configuration, particularly in relation to left-handed cases, will be discussed in further detail below.

[0065] The fixed erection unit 60 generally comprises a pair of fixed folding blades 601 a, 601 b, a retractable stop plate 602, and a case support 603. The fixed folding blades are arranged in parallel and spaced a distance apart from each other in the width direction on the z-axis. In this regard, one of the fixed folding blades is positioned proximal to the top end of case of the selected blank being unfolded while the other fixed folding blade is positioned proximal to the bottom end of the case of the selected blank being unfolded. Similar to the folding blade arranged on the pusher arm, each of the fixed folding blades comprises a straight segment and an arcuate segment. Here also, each arcuate segment is connected to the corresponding straight segment and is arranged so as to curve downward in a counterclockwise (ccw) direction therefrom. Each arcuate segment preferably has a respective length that corresponds to approximately one-quarter of a circle or about 90 degrees. Additionally, the fixed erection unit is positioned in the longitudinal direction (y) such that the fixed folding blades are arranged at generally the same height on the longitudinal axis (Y) as the folding blade. This facilitates that the minor case faces are made orthogonal to the major case faces (i.e., squared) of a selected blank during unfolding.

[0066] As can be seen in Fig. 7, the stop plate 602 and the case support 603 are generally arranged in between the fixed folding blades in the z-direction. In this non-limiting example, the stopplate is arranged proximal to the bottom end of the case of the selected blank being unfolded while the case support is positioned proximal to the top end of the case of the selected blank being unfolded. However, it is possible that the positioning of the stop plate and the case support could be switched in other non-limiting embodiments.

[0067] In operation, the stop plate is actuated to extend a distance from the fixed erection unit in the transverse direction (x) and into contact with an unfolded, and preferably squared, blank. As illustrated in Fig. 7, the extended stop plate contacts and temporarily holds the unfolded blank until the pusher arm ‘grabs’ the unfolded blank and pushes it in the conveying direction (x) onto a transfer conveyor arranged behind the fixed erection unit in the conveying direction (x). It may also be appreciated that the unfolded blank is inhibited from reverting back into a folded or semi-folded configuration by the stop plate.

[0068] Once the unfolded blank has been ‘grabbed’ by the pusher arm, the stop plate is retracted, and the case support is raised as shown in Fig. 6. With the case support in the raised position, the case grip may then release the erected case so that it may continue to be conveyed over the fixed erection unit. Here, the case support assists to facilitate a smooth transfer of the unfolded blank in the conveying direction (x) over the fixed erection unit and onto a transfer conveyor (not shown).

[0069] Exemplary alignment of a right-handed case is shown in Figs. 8 and 9, and similarly, exemplary alignment of a left-handed case is shown and Figs. 10 and 11 . For reference, whether a blank to be constructed is a right-handed case or a left-handed case can be identified from its arrangement on the base frame. For a right-handed case 90R, the major case face 901 is positioned adjacent to the stop element 202 and the minor case face 902 is positioned adjacent to the x-axis stop element 710. In this sense, the minor case face 902 can be considered as arranged on the right-hand side of the set-up. Conversely, for a left-handed case 90L, the minor case face 902 is positioned adjacent to the stop element 202 and the major case face 901 is positioned adjacent to the x-axis stop element 710. The minor case face 902 of a left-handed case can thus be considered as arranged on the left-hand side of the set-up.

[0070] Alignment of a right-handed case 90R in an xz-plane of the case erector apparatus is shown in topview in Fig. 8. As previously discussed, the base frame comprises a portion between the second end edge and the last roller of the conveyor in which the stop element is moveable along the transverse axis (X). This portion of the base frame is the stop element adjustment zone 222. For a right-handed case, the stop element is essentially positioned opposite to the second end edge at the end of the stop element adjustment zone directly adjacent to the last roller. In this sense, the stop element can be considered to be positioned all the way forward in the stop element adjustment zone. As can be seen in Fig. 8, the right-handed case blank is therefore arranged almost entirely on the conveyor in the transverse direction (x). Only a relatively small portion of the blank extends over the last roller and overlies the stop element adjustment zone. For a right-handed case, the major case face is thus positioned against the stop element and the x-axis stop element 710 is positioned against the minor case face to effectuate alignment of the blank in the transverse direction (x). The blank is further aligned in the z-direction by z-axis stop elements 702, 703.

[0071] Alignment of an exemplary right-handed case is further shown in perspective view in Fig. 9. Again, a right-handed case blank is arranged on the base frame and aligned in the transverse direction (x) between the x-axis stop element and the stop element. From this view, it is possible to see that the stop element comprises a transverse base member 2021 and a plurality of prongs 2022. Each prong extends from the transverse base member in the longitudinal direction (y) and is spaced a distance a distance apart from any adjacent prong. Additionally, because the base frame can, in certain embodiments be translated along the longitudinal axis (Y), the respective extensions, or lengths, of the prongs will generally control the maximum number of blanks that can be loaded on the base frame for any given set of blanks.

[0072] Alignment of a left-handed case 90L in an xz-plane of the case erector apparatus is shown in topview in Fig. 10 and similarly in perspective view in Fig. 11. For a left-handed case, the stop element is positioned in the stop element adjustment zone 222 and spaced at a distance from the end of the stop element adjustment zone which is directly adjacent to the last roller of the conveyor. The distance from which the stop element is spaced from the last roller generally corresponds to the length of the minor case face of the left-handed case in the transverse direction (x). This length will be the width of the erected case in use. As can be seen in both Figs. 10 and 11 , the minor case face of the left-handed case is therefore arranged entirely on top of the stop element adjustment zone in the transverse direction (x). A relatively small portion of the major case face of the lefthanded case blank may also extend over the last roller and overlie the stop element adjustment zone while the remainder of the major case face overlies the conveyor. It further follows that, for a left-handed case, the minor case face is positioned against the stop element and the x-axis stop element is positioned against the major case face to effectuate alignment of the blank in the transverse direction (x).

[0073] In the exemplary, non-limiting embodiments of Figs. 10 and 11 , the blank is further aligned in the z-direction by the first z-axis stop element 702. Because the left-handed case is aligned further back on the stop element adjustment zone, the left-handed case does not extend as far on the conveyor as would an equivalently sized right-handed case. As such, the left-handed case does not extend far enough to reach the second z-axis stop element 703. Instead, the alignment arm 71 of the alignment member 70 is translated along the transverse axis (X) such that the x-axis stop element contacts the major case face of the left-handed case. Further, in such exemplary embodiments as those shown in Figs. 10 and 11 , the alignment arm is generally positioned between the first and second z-axis stop elements. However, it is to be understood that one of ordinary skill in the art may readily adjust the positioning of any one or more of the alignment arm, the first z-axis stop element, the second z-axis stop element, as desired, and particularly, but without limitation, to accommodate differently sized blanks.

[0074] Further, the fixed erection unit 60 is generally arranged above the base frame at the end of the stop element adjustment zone directly adjacent to the last roller. Having the fixed erection unit situated in this manner, enables the fixed folding blades to be aligned with particular folding edges of the left-handed and right-handed cases. This alignment, in turn, further facilitates construction of the blanks into fully erected cases. More specifically, the fixed erection unit is generally aligned withthe leading folding edge 903 of a right-handed case, as shown in Fig. 8, whereas for a left-handed case, the fixed erection is generally aligned with the trailing folding edge 904 between the major and minor case faces, as shown in Fig. 10.

[0075] The present disclosure also relates to a method for erecting right-handed or left-handed cases with the case erector apparatus described herein. In general, the method involves providing one or more blanks, aligning the one or more blanks, selecting the top blank from the one or more blanks, and erecting the selected blank into one of either a right-handed case or a left-handed case.

[0076] According to the method, one or more blanks are loaded on the base frame. Depending on the type of blanks, i.e., left-handed cases or right-handed cases, the one or more blanks are aligned in the corresponding load position for either right-handed cases or left-handed cases. Once the one or more blanks are aligned, the blank grabber arm is actuated to select a top blank from the one or more blanks. While the selected blank is being raised by the blank grabber arm, the selected blank is unfolded. How the method continues from this point depends on the type of blanks.

[0077] When the one or more blanks are right-handed cases, such as the exemplary cases depicted in Figs. 12 and 13, for example, the pusher arm is brought into contact with a minor case face of the selected blank to square the folding edge. The folding edge is ‘squared’ when the minor case face is made orthogonal to the major case face. Stated differently, in squaring the folding edge, a right angle is formed between the minor case face and the major case face. Squaring the folding edge in this manner renders the selected blank erected as a right-handed case. Further, the pusher arm is moved in the conveying direction (x) to discharge the erected right-handed case onto a transfer conveyor (not shown).

[0078] Turning to Fig. 12, the exemplary right-handed case is shown in a partially erected state. In this example, the selected blank is held by the blank gripper on the major case face adjacent to the leading folding edge 903. As the selected blank is raised, the blank will unfold from right to left, or in a counterclockwise (ccw) direction. That the blank is unfolded from right to left can also be recognized by the type of angles formed in the corners of the unfolding blank. Specifically, the top right-hand corner of the blank that is arranged proximal to the fixed erection unit and the opposing bottom left-hand corner arranged proximal to the folding blade on the pusher arm exhibit acute angles. While the selected blank is raised, the leading folding edge may be aligned with the fixed erection unit 60. The major case face is thus arranged so that it is parallel or essentially parallel with the straight segments of the fixed folding blades. Additionally, while the blank is held by blank grabber arm, the pusher arm is moved in the conveying direction (x) into contact with the minor case face 902 to square the folding edge and erect the blank as a right-handed case.

[0079] Alternatively, when the one or more blanks are left-handed cases, such as the exemplary cases depicted in Figs. 14 and 15, for example, the minor case face of the selected blank is brought into contact with the pair of fixed folding blades to square the folding edge. Squaring the folding edge in this manner renders the selected blank erected as a left-handed case. Thereafter, the squared folding edge is held in place with the retractable stop plate. The squared folding edge is held like this to prevent the squared folding edge from reverting into a semi-folded or fully folded configuration. While the squared folding edge is held, the pusher arm is moved in the conveyingdirection (x) into contact with the erected left-handed case. Upon contact, the case grip is meant to grip the erected left-handed case.

[0080] Once the erected left-handed case is gripped by the case grip, the stop plate is retracted to allow the left-handed case to be transferred in the conveying direction (x) by the moveable pusher arm. Accordingly, the pusher arm is moved in the conveying direction (x) to discharge the erected left-handed case onto a transfer conveyor (not shown).

[0081] For both left-handed and right-handed cases, the erected case may, in exemplary embodiments, be transferred in between two side belts. In such exemplary embodiments, the side belts are configured with grip suitable to transport the erected case and keep it squared. This is also typically the point at which the bottom of the erected case, the bottom flaps having already been folded inward, is subsequently closed and / or sealed. Closing of the bottom of the erected case can be effectuated, for example, by applying an adhesive like tape or a hotmelt glue.

[0082] Following retraction of the stop plate, a case support may also be extended from the fixed erection unit to facilitate smooth transfer of the erected left-handed case over the fixed erector unit and onto the transfer conveyor for subsequent discharge from the case erector apparatus.

[0083] Turning to Fig. 14, the exemplary left-handed case is shown in a partially erected state. In this example, the selected blank is held by the blank gripper on the major case face adjacent to the trailing folding edge 904 between the major case face 901 and the minor case face 902. As the selected blank is raised, the blank will unfold from left to right, or in a clockwise (cw) direction. That the blank is unfolded from left to right can also be recognized by the type of angles formed in the corners of the unfolding blank. Specifically, the top right-hand corner of the blank that is arranged proximal to the fixed erection unit and the opposing bottom left-hand corner arranged proximal to the folding blade on the pusher arm exhibit obtuse angles. While the selected blank is raised, the minor case face is brought into contact with the fixed folding blades to square the folding edge and erect the blank as a left-handed case.

[0084] In embodiments in which the case erector apparatus is provided with an optional lift, the method may further involve one or more additional steps. Particularly, after the one or more blanks are aligned in the load position, the base frame may be translated from the load position to a collection position. Additionally, in certain embodiments, translation of the base frame may be effectuated by incrementally raising the lift such that the top blank is arranged at the collection position.

[0085] In the case erector apparatuses described herein, the one or more blanks to-be-erected are generally arranged in a horizontal configuration relative to the base frame. In this sense, the one or more blanks typically lie flat on the base frame with a minor case face and a major case face positioned side by side in the transverse direction (x). For a right-handed case, this means that lying flat on the base frame, the blank has a major case face adjacent to the stop element and a minor case face adjacent to the x-axis stop element; the minor case face of a right-handed case is thus considered to be arranged on the right-hand side of the set-up. Conversely, for a left-handed case lying on the base frame, the blank has a major case face adjacent to the x-axis stop element and a minor case face adjacent to the stop element; the minor case face of the left-handed case is thusconsidered to be arranged on the left-hand side of the set-up. However, it is further contemplated that the case erector apparatus can be adapted to accommodate one or more blanks arranged in a configuration otherthan horizontal one, such as a vertical configuration or an angled configuration, relative to the base frame.

[0086] Regardless of the configuration of the set-up, whether for angled, horizontally, or vertically oriented blanks, it is contemplated that blanks may be fed to case erector apparatus individually, one by one, or alternatively, blanks may be provided in a plurality, such as a in a stack or magazine. With a vertical magazine, the blank(s) may be picked from the side opposite of which they are loaded by an operator. The magazine can thus always be filled, even during operation and does not require downtime of the line to be reloaded. By contrast, filling and selection of a blank from a horizontal magazine is done from above, typically from a stack or pile of a plurality of blanks. In any case, these configurations have advantages for a centralized, automatic distribution of blanks.

[0087] Fig. 16 depicts an exemplary set-up of the case erector apparatus adapted for erecting one or more vertically oriented blanks. Relative to the basic set-up of an exemplary case erector apparatus adapted for erecting one or more horizontally oriented blanks, which has generally been described herein as arranged in an xy-plane, the basic set-up is shifted for arrangement in an xz- plane to accommodate erecting one or more vertically oriented blanks. The set-up generally includes a blank grabber arm 40, a moveable pusher arm 50, and a fixed erection unit 60. A base frame, though not shown in Fig. 16, may also be included in the set-up.

[0088] Here, the blank grabber arm is arranged such that it has an extension in the case conveying direction along the x-axis between first and second opposing ends. The blank grabber arm is also adapted to be translatable in the blank opening direction along the z-axis from a start position to a collection position.

[0089] The pusher arm 50 is also arranged to have a length in the blank opening direction (z) between upper and lower ends and is adapted to be movable in the case conveying direction (x).

[0090] As can also be seen in Fig. 16, the fixed erection unit 60 is arranged generally in parallel with the lower end of the pusher arm. For erecting vertically oriented right-handed and left-handed case, the folding blade and pair of fixed folding blades are instead arranged with their arcuate segments positioned in the case conveying direction (x).

[0091] Apart from the shift in the plane of arrangement, operation of the case erector apparatus for vertically oriented blanks is otherwise performed in essentially the same manner as for horizontally oriented blanks and as previously discussed herein.

[0092] While the invention has been described herein by reference to certain embodiments, it is to be understood that modifications in addition to those described herein may be made to the structures and techniques described herein without departing from the spirit and scope of the invention. Accordingly, although specific embodiments have been described, they are examples only and are not limiting upon the scope of the invention.

Claims

Claims1 . A case erector apparatus comprising a blank grabber arm comprising a blank grip and having an extension in a case conveying direction along a case conveying axis of the case erector apparatus between first and second opposing ends, the blank grabber arm adapted to be translatable in a blank opening direction along a blank opening axis of the case erector apparatus from a start position to a collection position; a moveable pusher arm having a length in the blank opening direction between upper and lower ends and comprising a folding blade and a case grip; and a fixed erection unit comprising a retractable stop plate, a case support, and a pair of fixed folding blades, the fixed folding blades arranged in parallel and spaced a distance apart from each other on a case height axis.

2. The case erector apparatus according to claim 1 , further comprising a base frame which comprises a conveyor and a stop element.

3. The case erector apparatus according to claim 2, wherein the base frame further comprises a lift adapted to be translatable along the blank opening axis from a load position to a collection position.

4. The case erector apparatus according to claim 3, wherein the lift comprises a blank detector configured to detect when at least one blank is in the lift, the blank detector preferably comprising a capacitive switch.

5. The case erector apparatus according to claim 3 or claim 4, wherein the lift comprises a lift grip preferably configured to hold a bottom blank from a stack of a plurality of blanks arranged in the lift in contact with the conveyor, and wherein the lift grip preferably comprises a vacuum cup.

6. The case erector apparatus according to any one of claims 3 to 5, wherein the lift further comprises an actuator, the actuator preferably comprising a servomotor.

7. The case erector apparatus according to any one of claims 3 to 6, wherein the lift comprises a position sensor, the position sensor preferably arranged on the stop element.

8. The case erector apparatus according to any one of claims 2 to 7, wherein the stop element comprises a transverse base member and a plurality of prongs extending a length therefrom, each prong spaced a distance apart from any adjacent prong on the transverse base member.

9. The case erector apparatus according to any one of claims 2 to 8, wherein the stop element is adapted to be moveable along the case conveying axis preferably between a left-handed case position and a right-handed case position.

10. The case erector apparatus according to any one of the preceding claims, wherein the blank grip comprises at least one vacuum cup, preferably two vacuum cups and more preferably four vacuum cups.11 . The case erector apparatus according to any one of the preceding claims, wherein the blank grip is arranged to hold a blank on a major case face thereof at a position adjacent to a folding edge between the major case face and a minor case face.

12. The case erector apparatus according to any one of the preceding claims, wherein the folding blade is arranged at the lower end and the case grip is arranged above the folding blade.

13. The case erector apparatus according to any one of the preceding claims, wherein the folding blade comprises a straight segment and an arcuate segment arranged to come into contact with a minor case face of a right-handed case.

14. The case erector apparatus according to any one of the preceding claims, wherein the case grip comprises a plurality of vacuum cups.

15. The case erector apparatus according to any one of the preceding claims, wherein each fixed folding blade comprises a straight segment and an arcuate segment arranged to contact a minor case face of a left-handed case.

16. The case erector apparatus according to any one of the preceding claims, further comprising an alignment member adapted to align one or more blanks in a load position, the alignment member comprising at least case length stop element and at least one case height stop element.

17. The case erector apparatus according to claim 16, wherein the alignment member comprises an alignment arm adapted to be moveable in the case conveying direction, the alignment arm having a free end which comprises the case length stop element.

18. A method for erecting right-handed or left-handed cases, the method comprising providing the case erector apparatus according to any one of claims 1 to 17, loading one or more blanks, aligning the one or more blanks in a load position for either right-handed cases or lefthanded cases, actuating the blank grabber arm to select a top blank from the one or more blanks, the selected blank unfolding while being raised by the blank grabber arm, and wherein when the one or more blanks are right-handed cases, the method further comprisesbringing the pusher arm into contact with a minor case face of the selected blank to square the folding edge such that the selected blank is erected as a right-handed case, and moving the pusher arm in the conveying direction to discharge the erected right- handed case onto a transfer conveyor; or wherein when the one or more blanks are left-handed cases, the method further comprises bringing the minor case face of the selected blank into contact with the pair of fixed folding blades to square the folding edge such that the selected blank is erected as a lefthanded case, holding the squared folding edge in place with the retractable stop plate, moving the pusher arm in the conveying direction and gripping the erected lefthanded case with the case grip, retracting the stop plate, and moving the pusher arm in the conveying direction to discharge the erected lefthanded case onto a transfer conveyor.

19. The method according to claim 18, further comprising translating the one or more blanks aligned in the load position to a collection position.

20. The method according to claim 19, wherein translating the one or more blanks to the collection position comprises incrementally raising a lift of the case erector apparatus such that the top blank is arranged at the collection position.

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