Loader station for a converter machine

Abstract

A loader station (12) for acquisition of a loading stack (16) of blanks (6) to load into a feeder module (20) of a converting machine (4), the loader station comprising: an automated unit (36) arranged to implement: an extraction step of extracting said loading stack (16) of blanks from a stack arrangement of blanks; a support step to support the stack arrangement during said extraction step, and; a loading step, in which the extracted loading stack of blanks is loaded into the feeder module of the converting machine, and; electrical circuitry (10) arranged to control the automated unit to implement the extraction step, support step, and loading step.

Description

[0001] LOADER STATION FOR A CONVERTER MACHINE

[0002] TECHNICAL FIELD

[0003] The present disclosure relates to a loader station for a converting machine. In particular, the disclosure relates to a loader station suitable for loading stacks of blanks into a converting machine, examples of which include a folder-gluer machine.

[0004] BACKGROUND

[0005] Converting machines such as folder-gluers are used in the production of paperboard and cardboard boxes. These machines are configured to receive cut-to-shaped blanks and then fold and glue them to form folding boxes or other similar packaging elements.

[0006] The folder-gluer machine can be configured to fold and glue paperboard blanks together to form packaging elements such as pharmaceutical boxes. However, it is also possible to configure the folder-gluer machine to form larger packaging elements made from corrugated cardboard.

[0007] The folder-gluer machines comprise a feeder module which is configured to receive a stack of blanks. Sometimes the feeder of the folder-gluer machines is manually loaded by an operator who continuously replenishes the feeder module as it becomes empty of blanks. However, for long production runs and for large blanks, it is advantageous to provide an automatic loading of the feeder module.

[0008] The blanks supplied to the feeder module are often supplied on a pallet, with several stacks of blanks located side by side. A robot with a gripper arm can be used for gripping a partial stack of blanks and placing said partial stack in the feeder module. To avoid the stack of blanks from moving when the gripper arm enters into the stack, the stack of blanks can be placed against a mechanical wall frame.

[0009] However, a mechanic wall frame only allows the stacks to be held from one side. Due to the complex edge shape of the blanks in the stacks, a flat mechanical wall does not always provide a suitable holding surface.

[0010] SUMMARY

[0011] In view of the prior art, it is an object of the present disclosure is to provide an improved loader station for the blanks. This object may be solved by a loader station according to claim 1 . The present disclosure provides a loader station for acquisition of a loading stack of blanks to supply to a feeder module of a converting machine, the loader station comprising: an automated unit arranged to implement: an extraction step of extracting said loading stack of blanks from a stack arrangement of blanks; a support step to support the stack arrangement during said extraction step, and; a loading step, in which the extracted loading stack of blanks is supplied to (e.g. loaded into) the feeder module of the converting machine, and; electrical circuitry arranged to control the automated unit to implement: the extraction step; the support step, and; loading step.

[0012] By implementing an automated unit to support the stack arrangement, as a loading stack is extracted from the stack arrangement, with said support being arranged to facilitate said extraction (e.g. without movement or collapsing of the stack arrangement during extraction) a range of support conditions may be implemented, which may be adapted to different stack arrangement configurations.

[0013] In embodiments, the electrical circuitry is implemented as one or more processors, which are configured to implement control of the automated unit to execute the disclosed steps. The processors may execute program code stored on electronic memory and / or may execute programable logic, e.g., as a logic array, gate array, structured array etc.

[0014] As used herein the term “extraction step” may refer to the process of isolating the loading stack and extracting it so that it is separate from the stack arrangement. As used herein the term “support step” may refer the process of the application of a loading and / or support condition to facilitate the extraction step, e.g. to prevent movement and / or collapsing of the stack arrangement caused by the extraction step. Hence the support step maybe executed for the entirety of the extraction step, or just portions of the extraction step (e.g. during insertion of the insertion element and optional engagement of the holding mechanism), as will be discussed. The support step may also be executed before and / or after the extraction step, e.g. immediately before to ensure a settled stack under the associated support conditions prior to execution of the extraction step or after to ensure the stack has settled prior to removal of the support condition. As used herein the term “loading step” may refer to the loading / supply of the extracted loading stack to the converter machine.

[0015] In embodiments, the stack arrangement comprises a first stack from which the loading stack is extracted and one or more adjacent stack(s) arranged to adjoin (e.g. to be in contact with) a back wall of the first stack, and the support step comprises a first support condition in which the or each adjacent stack(s) are engaged by a movable support (e.g. of the automated unit) so that an adjoining face of an adjacent stack that adjoins the back wall of the first stack rigid (including substantially / sufficiently rigid) to restrain movement of the back wall.

[0016] By implementing a loading condition in which there are multiple adjoining stacks and a back wall of the first stack (from which the loading stack is extracted) rigidly supported through the adjacent stacks by means of a loading condition applied to the adjacent stacks (e.g. and not necessarily the first stack), advantageously, multiple stacks may be built up to adjoin each other and held in a self supporting manner, which may increase the storage capacity of the loader station compared to a single stack loader station.

[0017] In embodiments, the movable support engages a top surface of one or more of the adjacent stack(s) to apply a compressive force in a direction of stacking. By engaging a top surface of the one or more adjacent stacks, the entire back wall of the first stack may be rigidly supported.

[0018] In embodiments, the movable support engages backwall an adjacent stack in operative proximity to the loading stack. By engaging the back wall of an adjacent stack opposite to where the loading stack is to be extracted, the back wall of the loading stack of the first stack may be rigidly supported / restrained during the extraction step.

[0019] As used herein the term “operative proximity” in respect of the position of support of the back wall of an adjacent stack may refer to a region of the adjacent stack being supported so as to convey a rigid support around the loading stack of the first stack. For example, it may include a supported region of the adjacent stack which spans the same height parallel to the loading stack. It may include a greater sized region being supported such that a supported region extends beyond said same height as the loading stack, e.g. a 10% or 20% extension. The adjacent stack that directly adjoins the first stack may be supported in this manner, or an adjacent stack that adjoins an adjacent stack that directly adjoins the first stack may be supported in this manner.

[0020] In embodiments, the stack arrangement comprises a first stack (e.g. only a first stack and no adjacent stacks) from which the loading stack is extracted, and the support step comprises a second support condition in which a back wall of the first stack is engaged in operative proximity to the loading stack prior to extraction via a movable support (e.g. of the automated unit) to restrain movement of the backwall. In embodiments, the movable support is movable in height direction, the height direction aligned to a direction of stacking. By engaging the back wall of the first stack over the area of the loading stack that is to be extracted, the back wall of the loading stack may be rigidly supported during extraction. As used herein the term “operative proximity” in respect of the position of support of the back wall of the loading stack may refer to a region of the first stack being supported so as to convey a rigid support of the loading stack. For example, it may include a supported region of the first stack which spans the same height parallel to the loading stack. It may include a greater sized region being supported such that a supported region extends beyond said same height as the loading stack, e.g. a 10% or 20% extension.

[0021] In embodiments, the electrical circuitry is configured to implement the first loading condition and once the adjacent stacks are depleted implement the second loading condition. In embodiments, the electrical circuitry is configured to implement the second loading condition and once at least one adjacent stacks are added implement the first loading condition. By transitioning between the first to second loading conditions as the stacks are depleted / added, the loader station may supply a loading stack for a range of stack arrangements. The stack arrangement may be determined by a recognition module or other arrangement including data logging of stack movement / depletion.

[0022] In embodiments, the electrical circuitry implements: a recognition module to determine a configuration of the stack arrangement, and; the first or second support condition is implemented based on the determined configuration of the stack arrangement.

[0023] By implementing determination of the stack arrangement and selection of the appropriate support condition, the loader station may adaptively supply a loading stack for a range varying of stack arrangements.

[0024] In embodiments, the movable support is movable between a back wall engagement position and a top surface engagement position to implement the support step. By having a movable support that can rotate between top and side supporting conditions, a range of stack arrangements may be processed.

[0025] In embodiments, the support step comprises supporting the stack arrangement to prevent the stack arrangement from collapsing / moving during the extraction step. By preventing the stack arrangement from moving to an extent that extraction of the loading stack is impeded (e.g. a small movement may still be possible), a range of stack arrangements may be processed.

[0026] In embodiments, the automated unit is implemented as: a first robot for the acquisition step, and; a second robot for the support step. A first and separate second robot may be specifically configured to implement the extraction step and the supporting step respectively. In embodiments, the first and second robot are independently controllable, that is they may operate as entirely separate units. In embodiments, the first and second robot are independently controllable by 6 degrees of freedom (e.g. 3 translational degrees of freedom and 3 rotational degrees of freedom).

[0027] In embodiments, the first and / or second robot comprise: an arm for actuating a movable support (for the second robot) or an extraction implement (for the first robot); a base supporting the arm, and; an actuation system, controlled by the electrical circuitry for control of the arm.

[0028] In embodiments, the arm of the first robot is rotatable between: an extraction position for execution of the extraction step, and; a loading position for execution of the loading step. By implementing the robot to rotate between the said positions the loading stack may be conveniently extracted and loaded.

[0029] In embodiments, the automated unit comprises: a movable support for support of the stack arrangement to implement the support step, wherein the movable support comprises an adaptive support surface to adapt in shape to correspond to a shape of the stack arrangement. By implementing the movable support to have a support surface that can adapt its profile to match the particular blanks forming the stack arrangement, more secure support may be provided.

[0030] In embodiments, the automated unit comprises an extraction implement for extraction of the loading stack from the stack arrangement, the extraction implement comprising: an insertion element for insertion into the stack arrangement, and: a holding mechanism to press the loading stack against the insertion element. By implementing an extraction implement to have an insertion element (e.g. a parting blade), the insertion element may be inserted between the blanks to separate the loading stack from the first stack of the stack arrangement and the holding mechanism can clamp the loading stack together so that it may be conveniently isolated, extracted and loaded.

[0031] In embodiments, the loader station comprises a transportation system for transportation of a stack of blanks to an extraction position, in which the stack forms the stack arrangement (which is arranged for extraction of the loading stack from the first stack thereof). The transportation system may transport subsequent stacks to replenish the stack arrangement once the first and / or adjacent stacks have been depleted such that the loader station may supply loading stacks continuously.

[0032] In embodiments, the transportation system comprises at least one ora plurality of inlet conveyors, and; the extraction position is arranged with a rotating support platform configured to receive the stack of blanks from the inlet conveyors, and position the received stack to comprise the stack arrangement.

[0033] The present disclosure provides a method of loading a blanks (e.g. a loading stack) into a feeder module of a converting machine. The method comprising: extracting a loading stack of blanks from a stack arrangement of blanks; supporting the stack arrangement during said extraction, and; loading the extracted loading stack of blanks into the feeder module of the converting machine. The method may comprise the features of any preceding embodiment or another embodiment disclosed herein. The method may be implemented with an automated unit.

[0034] The present disclosure provides electrical circuitry or a computer program (e.g. machine readable code) executable on one or more processors to control an automated unit to perform the method and / or another method disclosed herein.

[0035] The preceding summary is provided for purposes of summarizing some embodiments to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the abovedescribed features are merely examples and should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and / or proceeding embodiments may be combined in any suitable combination to provide further embodiments. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following Detailed Description of Embodiments, Brief Description of Figures, and Claims.

[0036] BRIEF DESCRIPTION OF FIGURES

[0037] Aspects, features and advantages of embodiments of the present disclosure will become apparent from the following detailed description of embodiments in reference to the appended drawings in which like numerals denote like elements.

[0038] Figure 1 is a block system diagram showing a system comprising a converting machine, a loader station, blanks arranged as a stack, and objects formed by the blanks.

[0039] Figure 2 is a schematic diagram showing a converting machine in the configuration of a folder gluer of the system of figure 1 .

[0040] Figure 3 is a plan view showing a blank of the system of figure 1 . Figure 4 is perspective view showing an object arranged as a folding box formed from the blank of figure 3 by the system.

[0041] Figure 5 is a schematic diagram showing the converting machine and the loader station of system figure 1 .

[0042] Figures 6 - 8 are a schematic diagrams showing the loader station of the system figure 5 in various configurations.

[0043] Figure 9 is a schematic plan view showing a positioning surface of the loader station of figure 5.

[0044] Figures 10 and 11 are a perspective view and a top view showing an extraction implement of the loader station of figure 5

[0045] Figure 12 is a side view of a movable support of the loader station of figure 5.

[0046] DETAILED DESCRIPTION OF EMBODIMENTS

[0047] Before describing several embodiments of the system, it is to be understood that the system is not limited to the details of construction or process steps set forth in the following description. It will be apparent to those skilled in the art having the benefit of the present disclosure that the system is capable of other embodiments and of being practiced or being carried out in various ways.

[0048] The present disclosure may be better understood in view of the following explanations:

[0049] As used herein the term “system for repetitive formation of objects from a blank” or “system” may refer to an arrangement that includes hardware comprising a converting machine for repetitively executing a formation process in a predefined manner for the formation of a objects from blanks, and a loader station to load the blanks into the converter machine. The system may implement the converting machine and loader station as part of a manufacturing line, which can include one or more of a printing machine; gluing machine; filling machine, and; a assembling machine. The converting machine may also implement any of the aforesaid machine processes.

[0050] As used herein the term “converting machine” may refer to hardware for executing a formation process for full or partial formation of an object. The hardware may be arranged as modules, e.g. in distributed in series or as a single unit. The converting machine may be configured to at least partially form the object from the blank. The converting machine includes a tool which is manipulated / driven for repetitive mechanical engagement with the blank to at least partially form said object during the formation process. The converting machine may include a feeder module, which is arranged to receive a stack of blanks on which the formation processes are executed.

[0051] As used herein the term “formation process” may refer to a process executed by the converting machine on the blank to at least partially form the object.

[0052] As used herein the term “loader station” may refer to an automated system, which is arranged to load blanks, in a stack, into a feeder module of a converting machine. The loader station may include an automated unit which is controlled to supply the stack to the feeder module in a fully or partially automated manner. The automated unit may extract the stack of blanks from a stack arrangement.

[0053] As used herein the term “stack arrangement” may refer to an arrangement of one or more stacks of blanks from which the loading stack of blanks is extracted. In the case of more than one stack of blanks, the stacks are arranged in a supporting manner, e.g. with a face of a stack directly adjoining another.

[0054] As used herein the term “loading stack” may refer to a sub-stack that is extracted from the stack arrangement, the sub-stack being sized to be accommodated by the feeder module.

[0055] As used herein the term “blank” may refer to a planar arrangement of sheet material from which an object may be formed, for example by one or more of folding, cutting and gluing. The blank may be formed from paperboard, cardboard, fibreboard, or other suitable material.

[0056] As used herein the term “object” may refer to the item formed by the formation process. The object can refer to packaging element or other like arrangement.

[0057] As used herein the term “paperboard” or “cardboard” may refer to paper pulp-based board. A thickness of the material may be greater than 0.30 mm and / or a grammage of a grammage above 250 g / m2, hence to distinguish the material from paper. Paperboard maybe single-ply or multi-ply.

[0058] As used herein the term “fibreboard” may refer to wood product that is made out of wood fibres or a kraft-based paperboard. It may include a kraft-based paperboard or corrugated fiberboard.

[0059] As used herein, the term "electrical circuitry" or "circuitry" or "control electrical circuitry" may refer to one or more hardware and / or software components, examples of which may include: one or more of an Application Specific Integrated Circuit (ASIC) or other programable logic; electronic / electrical componentry (which may include combinations of transistors, resistors, capacitors, inductors etc); one or more processors (e.g. circuitry structure of the processor); a non-transitory memory (e.g. implemented by one or more memory devices), that may store one or more software or firmware programs; a combinational logic circuit; interconnection of the aforesaid. The electrical circuitry may be located entirely at one component of the system, or distributed between a plurality of components of the system (e.g. a server system and / or external device) which are in communication with each other over a computer network via communication resources.

[0060] As used herein, the term "processor" or "processing resource" may refer to one or more units for processing, examples of which include an ASIC, microcontroller, FPGA, microprocessor, digital signal processor (DSP), state machine or other suitable component. A processor may be configured to execute a computer program, e.g. which may take the form of machine readable instructions, which may be stored on a non-transitory memory and / or programmable logic. The processor may have various arrangements corresponding to those discussed for the circuitry, e.g. on-board or distributed as part of the system. As used herein, any machine executable instructions, or computer readable media, may be configured to cause a disclosed method to be carried out, e.g. by the system or components thereof as disclosed herein, and may therefore be used synonymously with the term method, or each other.

[0061] As used herein, the term "computer readable medium / media" or "data storage" may include any medium capable of storing a computer program, and may take the form of any conventional non-transitory memory, for example one or more of: random access memory (RAM); a CD; a hard drive; a solid state drive; a memory card; a DVD. The memory may have various arrangements corresponding to those discussed for the circuitry.

[0062] As used herein, the term "communication resources" or "communication interface" may refer to hardware and / or firmware for electronic information transfer. The communication resources / interface may be configured for wired communication (“wired communication resources / interface”) or wireless communication (“wireless communication resources / interface”). Wireless communication resources may include hardware to transmit and receive signals by radio and may include various protocol implementations e.g. the 802.11 standard described in the Institute of Electronics Engineers (IEEE) and Bluetooth™ from the Bluetooth Special Interest Group of Kirkland Wash. Wired communication resources may include; Universal Serial Bus (USB); High-Definition Multimedia Interface (HDMI) or other protocol implementations. The converting machine may include communication resources for wired or wireless communication with an external device and / or server system.

[0063] As used herein, the term "network" or "computer network" may refer to a system for electronic information transfer between a plurality of apparatuses / devices. The network may, for example, include one or more networks of any type, which may include: a Public Land Mobile Network (PLMN); a telephone network (e.g. a Public Switched Telephone Network (PSTN) and / or a wireless network); a local area network (LAN); a metropolitan area network (MAN); a wide area network (WAN); an Internet Protocol Multimedia Subsystem (IMS) network; a private network; the Internet; an intranet; personal area networks (PANs), including with Bluetooth a short-range wireless technology standard.

[0064] As used herein, the term “external device” or "external electronic device" or “peripheral device” may include electronic components external to the converting machine, e.g. arranged at a same location or remote therefrom, which communicate therewith over a computer network. The external device may comprise a communication interface for communication with the machine and / or a server system. The external device may comprise devices including: a smartphone; a PDA; a video game controller; a tablet; a laptop; or other like device.

[0065] As used herein, the term “server system” may refer to electronic components external to converting machine, e.g. arranged at a same location or remote therefrom, which communicate therewith over a computer network. The server system may comprise a communication interface for communication with the converting machine or the external device. The server system can include: a networked-based computer (e.g. a remote server); a cloud-based computer; any other server system.

[0066] [General system description]

[0067] Referring to figure 1 a system 2 comprises: a converting machine 4; blanks 6; an object 8; a loader station 10 and; electrical circuitry 12.

[0068] The loader station 10 implements a loading process under the control of the electrical circuitry 12 to provide, from a stack arrangement 14 of blanks 6, a loading stack 16 of blanks 6 to the converting machine 4. The electrical circuitry 12 is arranged at the loader station 10.

[0069] In variant embodiments, which are not illustrated the electrical circuitry may be distributed over one or more components of the system, including an external device and / or server system. The converting machine 4 implements a formation process under the control of electrical circuitry to form the object 8, from a blank 6 from the loading stack 16.

[0070] The loader station 10 may be implemented with in converting machines 4 including: folder-gluers: rotary die-cutters; printing press machines, and; other like arrangements. In order to simplify the present description, reference is made to a folder-gluer machine.

[0071] [Converting machine]

[0072] Referring to figures 2 to 5, which illustrate a folder-gluer machine 4 and blanks 6 to be processed therein, the folder-gluer machine 4 is configured to receive the cut- to-shaped blank 6 (figure 3), and then fold and glue the blank 6 to form a folding box 8 (figure 4) or other folded and glued packaging containers as examples of the object 8. The cut-to-shaped blanks 6 are provided with crease-lines which allow folding of the blanks 6. These types of packaging containers 8 are provided in a sheet form at the outlet portion of the folder-gluer machine 4. The blanks 6 are conveyed along a transportation path through the converting machine 4.

[0073] The folder-gluer machine 4 comprises a series of different workstations in the form of modules. The modules may include, from an inlet to an outlet and in a direction of transportation T: a feeder module 20, an alignment module 22, a fold pre-breaking module 24, a gluing module 26 and a folding module 28. The folder-gluer machine 4 may further comprise a main user interface 30.

[0074] Downstream of the gluing and folding modules 26, 28 the converting machine 4 may further comprise a delivery section 32 configured to bundle or group a plurality of folding boxes 8 together.

[0075] As best seen in figure 2, the feeder module 20 comprises a loading surface 34 configured to receive a stack of cut-to-shaped blanks 6.

[0076] [Loader station]

[0077] Referring to figure 1 and 5 the loader station 12 is for acquisition of the loading stack 16 of blanks to load into the feeder module 20 of the converting machine 4. The loader station 12 comprises an automated unit 36 arranged to implement: an extraction step of extracting said loading stack 16 of blanks 6 from the stack arrangement 14 of blanks 6; a support step to support the stack arrangement 14 during said extraction step, and; a loading step, in which the extracted loading stack 16 of blanks 6 is loaded into the feeder module 20 of the converting machine 4. The electrical circuitry 10 arranged to control the automated unit 36 to implement the extraction step, support step, and loading step.

[0078] [Example loader station]

[0079] [Automated unit]

[0080] Referring to figures 5 to 8, the automated unit 36 is implemented as a first robot 38 for the acquisition step, and; a second robot 40 for the support step. The first robot 38 and the second robot 40 being independently controllable of each other by the electrical circuitry 10.

[0081] The components of the system 2 are arranged with a coordinate system having a longitudinal direction 100 and a lateral direction 102 that define a plane which is normal to a depth direction 104, which extends from a support base in a counter height direction.

[0082] Referring to figure 5 and 6, the first robot 38 includes: an arm 42 for actuating at a distal end an extraction implement 44 (as will be discussed); a base 46 supporting the arm 42 at a proximal end, (where proximal and distal are defined relative the base 46) and; an actuation system 48, controlled by the electrical circuitry 10, for actuation of the arm 42 and the extraction implement 44.

[0083] The second robot 40 implements the same features as for the first robot 38, which for brevity are not described, with the exception of a movable support 50 being actuated instead of the extraction implement 44.

[0084] The arm 42 at the proximal end is rotatably supported on the base 46 to rotate about a first axis aligned to the depth direction 104. The arm includes a first part 52 and a second part 54. A proximal end of the first part 52 is rotatably connected to the base 46 about a second axis orientated in the plane defined by the longitudinal direction 100 lateral direction 102, the second axis is rotatable in said plane via the first axis. A distal end of the first part 52 is rotatably connected to a proximal end of the second part 54 about a third axis orientated in the plane defined by the longitudinal direction 100 lateral direction 102, the third axis is rotatable in said plane via the first axis. A distal end of the second part 54 is rotatably connected to the extraction implement 44 about a fourth axis and a fifth axis, the fourth axis is aligned to an direction of elongation of the second part 54 and the fifth axis is normal to the fourth axis. The actuation system 48 implements rotational position control of the arm 42 about the first to fifth axis. The actuation system 48 implements any suitable drive system, e.g. one or more of: a motor drive; hydraulic; pneumatic; linear actuator, including solenoid; other suitable system.

[0085] A position of the arm 42 can be determined by a suitable position determination system (not illustrated) e.g. one or more of: rotary encoders; position sensors; image processing of an image stream from a camera system; laser position sensors, and; other suitable system. The position determination system may be implemented by the electrical circuitry 10 as part of a control system. For example, input of the control system may be the determined current position of the extraction implement 44 and an output may be a desired position, determined by a target position.

[0086] It will therefore be understood that the first robot 38 and second robot 40 are independently controllable by 6 degrees of freedom (e.g. 3 translational degrees of freedom and 3 rotational degrees of freedom).

[0087] In variant embodiments, which are not illustrated, other implementations of the automated unit include: a single robot, which can actuate both the extraction implement and the movable support; different implementations of the first and / or second robot, e.g. a single first part or an additional third part, implementation of slidable parts, e.g. telescopic arrangements.

[0088] The first robot 38 is actuatable to move the extraction implement 44 between an extraction position (figures 6 - 8) for execution of the extraction step, and a loading position (see left side of figure 5) for execution of the loading step. Other position may also be implemented.

[0089] In a similar manner, the second robot 40 is actuatable to move the movable support 50 between a back wall engagement position (figure 8) and a top surface engagement position (figures 5 - 7) to implement the support step, as will be discussed. Other position may also be implemented.

[0090] [Extraction Implement]

[0091] Referring to figures 10 and 11 , the first robot 38 of automated unit 36 comprises the extraction implement 44 for extraction of the loading stack 16 from the stack arrangement 14 (not illustrated in figure 10 and 11).

[0092] The extraction implement 44 is movable between open (not illustrated) and closed positions (figure 11). In the open position the extraction implement 44 is insertable into the stack arrangement 14 to separate the loading stack 16. In the closed position the extraction implement 44 grips the separated loading stack 16. The extraction implement 44 is moved from the closed position to the open position to release a gripped loading stack to the feeder module 20 of the converting machine 4.

[0093] The extraction implement 44 comprises an insertion element 60 for insertion into the stack arrangement 14, and: a holding mechanism 62 to press the loading stack 16 against the insertion element 14.

[0094] The insertion element 60 is arranged as two outer blades separated in local lateral direction 102 about a central blade for insertion proximal lateral opposed ends of the stack arrangement 14.

[0095] The holding mechanism 62 comprise two supports which are arranged opposed to the outer blades in the local depth direction 104, which are actuatable relative the blades in the depth direction 104 to press blanks of a loading stack therebetween onto the blades.

[0096] The insertion element 60 is inserted into a front wall of the stack arrangement 14 and the holding mechanism 62 engages with a top wall of the stack arrangement 14, as will be discussed.

[0097] The supports are actuatable relative the blades in the local depth direction 104 by an actuation system (not illustrated), suitable examples of which were provided for the arm, which is controlled by the electrical circuitry 10. The supports and blades may also be actuatable in the local lateral direction 102 by the actuation system to accommodate different sized blanks 6.

[0098] To eject the loading stack from the extraction implement 44 an ejector (not illustrated) comprises a conveyor arranged on the central blade or other pushing system.

[0099] The extraction implement 44 is configured to extract a loading stack of about 30 cm in depth, which may comprise up to about 50 blanks, depending on the thickness of the individual blanks. The hence a depth distance 104 between the insertion element 60 and the holding mechanism 62 in the closed position can correspond to this distance and the open position can correspond to a greater distance.

[0100] In variant embodiments, which are not illustrated, other extraction implements may be provided, for example: the holding mechanism maybe omitted; the extraction implement may comprise other numbers of blades, e.g. a single central blade or 4 blades; the blades may be inserted into a side wall of the stack arrangement. [Movable support]

[0101] Referring to figure 12 the second robot 40 of the automated unit 36 comprises the movable support 50 for support of the stack arrangement to implement the support step, as will be discussed.

[0102] The movable support 50 comprises an adaptive support surface 64 to adapt in shape to correspond to a shape of the stack arrangement 14. In particular, the adaptive support surface 64 is arranged as a plurality of engagement members, which are independently controllable in the local longitudinal direction 100 relative the distal end of the arm 42. The engagement members are disposed in the local lateral direction 102 and / or the local depth direction 104. In the illustrated example, there are four laterally arranged rows, each row with a different depth position. In variant embodiments, which are not illustrated, other arrangements are implemented.

[0103] The engagement members are actuatable by an actuation system (not illustrated), suitable examples of which were provided for the arm, which is controlled by the electrical circuitry 10.

[0104] [Transportation system]

[0105] Referring to figure 9, loader station 12 comprises a transportation system 70 for transportation of a subsequent stack 72 of blanks to an extraction position 74, in which the stack arrangement 14 is positioned for extraction of the loading stack 14.

[0106] The transportation system 70 may transport subsequent stacks 72 once a first and / or adjacent stacks of the stack arrangement 14 have been depleted such that the loader station 12 may supply loading stacks continuously, as will be discussed.

[0107] The transportation system 70 comprises two inlet conveyors 76 to supply the subsequent stacks 72 to the extraction position 74. The extraction position 74 is arranged with a rotating support platform 78, which is rotatable about an axis aligned to the depth direction 104 to selectively receive the subsequent stack 72 from either of the inlet conveyors 76. The rotating support platform 78 preferably comprises a first and a second conveyor located side by side.

[0108] In variant embodiments, which are not illustrated, the transportation system is alternatively configured, for example: other number of inlet conveyors; a non-rotatable support platform and a single conveyor; a pick and place system rather than a conveyor system; the conveyor system may be implemented as a belt and / or rollers. [Stack recognition]

[0109] The electrical circuitry 10 implements a recognition module (not illustrated) to determine a configuration of the stack arrangement 14.

[0110] The recognition arrangement is configured with one or more of: image processing based on an image stream from a camera system; position sensors, e.g. infra-red or lasers; a supply loggingbased system based on the number of subsequent stacks supplied and a number of loading stacks extracted; other suitable implementations. The recognition arrangement may be mounted on a fixed frame arranged above the extraction position 74.

[0111] The electrical circuitry 10 may implement a first or second support condition for the stack arrangement 14 based on the determined configuration of the stack arrangement by the recognition arrangement, as will be discussed.

[0112] The electrical circuitry 10 may implement supply of subsequent stacks 72 based on the determined configuration of the stack arrangement 14 by the recognition arrangement as will be discussed.

[0113] [Support conditions]

[0114] [First support condition]

[0115] Referring to figure 6, the stack arrangement 14 comprises a first stack 80 from which the loading stack 16 is extracted. The first stack has a front wall 82 and an opposed back wall 84, both of which are interconnected by side walls 86 and a top surface 92.

[0116] The stack arrangement 14 comprises a first adjacent stack (referred to as a second stack) 88, and a second adjacent stack (referred to as a second stack) 90. The second stack 88 is arranged to adjoin the back wall 84 of the first stack 80, and the third stack 90 adjoins the second stack 88. The second stack 88 and the third stack 90 have a corresponding front wall 82 and an opposed back wall 84, both of which are interconnected by side walls 86 and a top surface 82.

[0117] With the stack arrangement 14 in said configuration, a first support condition is implemented by the movable support 50 in which, the second stack 88 and the third stack 90 are engaged by the movable support 50 at both top surfaces 92 to apply a compressive force through both stacks. Hence the movable support 50 is arranged in a plane defined by the longitudinal direction 100 and the lateral direction 102. In this way, a rigid support is provided by the front wall 82 of the second stack 88 that adjoins the back wall 84 of the first stack 80. Said rigid wall provides a restraining support as the insertion element 60 of the extraction implement 44 is inserted into the first stack 80 and prevents the blanks of the loading stack 16 from moving with the insertion element 60. In a non-illustrated variant, only the third stack or second stack is supported.

[0118] Referring to figure 7, in a variant of the first support condition, as the first stack 80 of figure 6 is depleted, so that the second stack 88 has the loading stack 16 extracted therefrom, only a single adjacent stack is present, hence the movable support 50 applies a compressive force through the top surface 92 of the third stack 90.

[0119] There are often nick points / connection points between the blanks in each. By pressing on an adjacent stack from the top, it is possible to separate and pick up blanks in the loading stack without accidentally extracting blanks from the adjacent stack. Hence, the extraction implement of the first robot may pull the loading stack out such that these nick points / frangible lines rupture.

[0120] In a variant embodiment of the first support condition, which is not illustrated, the movable support 50 is alternatively arranged is arranged in a plane defined by the depth direction 104 and the lateral direction 102 to: support the backwall 84 of the third stack 90 (for the arrangement of figure 6), or; to support the back wall 84 of the second stack 88 (for the arrangement of figure 7). The back wall 84 can be supported in this manner in operative proximity of the loading stack 16 (as discussed following for the second loading condition). By supporting said back wall 84 in this manner, movement of the blanks is prevented in the longitudinal direction 100. In a variant, the entire back wall 84 may be supported in this manner.

[0121] [Second support condition]

[0122] Referring to figure 8, as the second stack 88 of figure 7 is depleted, so that the third stack 90 becomes the stack from which the loading stack 16 is extracted, and no adjacent stack is present, the movable support 50 is arranged to provide a second support condition.

[0123] In the second support condition, the movable support 50 is arranged in a plane defined by the lateral direction 102 and the depth direction 104. The back wall 84 of the third stack 90 is engaged in operative proximity (e.g. over at least a corresponding depth position to) to the loading stack 16 by the movable support 50 to restrain movement of the backwall 84 in the longitudinal direction 100. The second supporting condition provides a restraining support as the insertion element 60 of the extraction implement 44 is inserted into the third stack 90 and prevents the blanks of the loading stack 16 from moving with the insertion element 60.

[0124] The movable support 50 is movable in the depth direction 104, such that as the third stack 90 is depleted, the movable support moves 50 to support subsequent loading stacks 16 that are extracted. Hence a depth of the movable support 50 may be selected to correspond to the depth of the loading stack 16 with an additional depth portion to extend beyond the loading stack 16, e.g. by 2 - 10 or 2 - 5 blanks.

[0125] [Method of operation]

[0126] A method of implementing a loading process for supplying loading stacks 16 to a feeder module 20 of the converting may comprise:

[0127] Step 1 : a plurality of stacks 72 are supplied by the transport system 70 (figure 9) of the loader station 12 to provide a stack arrangement of figures 5 and 6. The configuration of the stack arrangement 14 can be determined by the recognition system (and also for the subsequent steps).

[0128] Step 2: the first loading condition of figure 6 is implemented to compress, with the movable support 50, the second and third stacks 88, 90. The extraction implement 44 is arranged with the insertion element 60 inserted into the first stack 80 to select the loading stack 16 and the holding mechanism 62 is moved to from the open to the closed position to hold the loading stack 16 against the insertion element 60. The loading stack 16 is then extracted from the first stack 80 and transferred to the feeder module 20 (left side of figure 5). The first loading condition may be maintained until the loading stack has been extracted from the first stack 80. Further loading stacks 16 are extracted from the first stack 80 (not illustrated). As the first stack 80 is depleted, the movable support 50 maintains the first loading condition.

[0129] Step 3: as the first stack 80 is determined as fully depleted, either: a subsequent stack 72 is supplied by the transport system 70 to restore the stack arrangement 14 to the configuration of figure 6, and steps 1 and 2 are executed, or; the first loading condition is implemented to compress with the movable support 50 the third stack 90 as shown in figure 7, and the extraction implement 44 is operated as for the second step and the loading condition is maintained as the first stack is depleted as for the second step.

[0130] Step 4: as the second stack 88 is determined as fully depleted, either: a subsequent stack is supplied 72 by the transport system 70 to restore the stack arrangement 14 to the configuration of figure 6 or 7, and step 3 is executed, or; the second loading condition is implemented to retain with the movable support 50 the back wall of the third stack 90, as shown in figure 8, and the extraction implement 44 is operated as for the second step and the loading condition is maintained as the loading stack 16 is extracted. Further loading stacks 16 are extracted from the third stack 90. As the third stack 90 is depleted, the movable support 50 is sequentially moved in the depth direction 104 to correspond in position to each loading stack 16.

[0131] Variants of the above method are to be completed, including those that may introduced by the various embodiments disclosed herein.

Claims

CLAIMS1 . A loader station for acquisition of a loading stack of blanks to supply to a feeder module of a converting machine, the loader station comprising: an automated unit arranged to implement: an extraction step of extracting said loading stack of blanks from a stack arrangement of blanks; a support step to support the stack arrangement during said extraction step, and; a loading step, in which the extracted loading stack of blanks is supplied to the feeder module of the converting machine, and; electrical circuitry arranged to control the automated unit to implement: the extraction step; the support step, and; loading step, wherein the stack arrangement comprises a first stack from which the loading stack is extracted and one or more adjacent stack arranged to adjoin a back wall of the first stack, and the support step comprises a first support condition in which the / or each adjacent stack(s) are engaged by a movable support of the automated unit so that an adjoining face of an adjacent stack that adjoins the back wall of the first stack is substantially rigid to restrain movement of the back wall.

2. The loader station of claim 1 , wherein the movable support engages: a top surface of one or more of the adjacent stack(s) to apply a compressive force in a stacking direction of stacking, and / or; a backwall of an adjacent stack in operative proximity to the loading stack.

3. The loader station of claim 1 wherein, the stack arrangement comprises a first stack from which the loading stack is extracted, and the support step comprises a second support condition in which a back wall of the first stack is engaged in operative proximity to the loading stack prior to extraction via a movable support of the automated unit to restrain movement of the backwall,wherein the movable support is movable in height direction, the height direction aligned to a direction of stacking.

4. The loader station of any one of claims 1 to 3, wherein the electrical circuitry is configured to implement the first loading condition and once the adjacent stacks are depleted implement the second loading condition.

5. The loader station of claim 4, wherein the electrical circuitry implements: a recognition module to determine a configuration of the stack arrangement, and; the first or second support condition is implemented by the electrical circuit based on the determined configuration of the stack arrangement.

6. The loader station of any of claims 1 - 5, wherein the movable support is movable between a back wall engagement position and a top surface engagement position to implement the support step.

7. The loader station of any preceding claim, wherein the support step comprises supporting the stack arrangement to prevent the stack arrangement from collapsing / moving during the extraction step.

8. The loader station of any preceding claim, wherein the automated unit is implemented as: a first robot for the extraction step, and; a second robot for the support step, wherein the first and second robot are independently controllable.

9. The loader station of claim 8, wherein the first and / or second robot comprises: an arm for actuating a movable support or an extraction implement; a base supporting the arm, and; an actuation system, controlled by the electrical circuitry for control of the arm.

10. The loader station of either of claims 8 or 9, wherein the first and second robot are independently controllable by 6 degrees of freedom.11 . The loader station of either of claims 9 or 10, wherein the arm of the first robot is rotatable between: an extraction position for execution of the extraction step, and; a loading position for execution of the loading step.

12. The loader station of any preceding claim, wherein the automated unit comprises: a movable support for support the stack arrangement to implement the support step, wherein the movable support comprises an adaptive support surface to adapt in shape to correspond to a shape of the stack arrangement.

13. The loader station of any preceding claim, wherein the automated unit comprises an extraction implement for extraction of the loading stack from the stack arrangement, the extraction implement comprising: an insertion element for insertion into the stack arrangement, and: a holding mechanism to press the loading stack against the insertion element.

14. The loader station of any preceding claim, comprising a: transportation system for transportation of a stack of blanks to an extraction position, in which the stack forms the stack arrangement.

15. The loader station of the claim 14, wherein: the transportation system comprises a plurality of inlet conveyors, and; the extraction position is arranged with a rotating support platform configured to receive the stack of blanks from the inlet conveyors.

16. A method of loading blanks into a feeder module of a converting machine, the method comprising, with an automated unit: extracting a loading stack of blanks from a stack arrangement of blanks; supporting the stack arrangement during said extraction, and;loading the extracted loading stack of blanks into the feeder module of the converting machine.

Images