Machine for manufacturing cardboard pallet components

Abstract

The present invention relates to a machine for manufacturing cardboard pallet components from plates made of flexible material. The machine comprises a first zone (Z1) that receives the corresponding element made of flexible laminar material (for example, cardboard) and has a conveying system; a second zone (Z2) with at least one tray from which the parts made of flexible laminar material arriving from the first zone (Z1) are removed by the conveying system (which preferably has vacuum suction cups) and are deposited on a device for conveying same to the following zone; a third zone (Z3) where the parts made of flexible laminar material removed in the second zone (Z2) are stored in a dosing device and are deposited on a surface that receives said sheets and inserts them into the following processing zone; and a fourth zone (Z4) where the shaping operations corresponding to the shaping module are carried out and the processed parts are conveyed to a module arranged after this shaping module.

Description

[0001] MACHINE FOR MANUFACTURING CARDBOARD PALLET COMPONENTS

[0002] DESCRIPTION

[0003] OBJECT OF THE INVENTION

[0004] The present invention falls within the technical field of manufacturing loading platforms from flexible sheet material, such as cardboard. Specifically, it describes a forming module for assembling elements and assemblies from cardboard sheets. That is, it is a forming module for supplying pre-formed cardboard sheets to a cardboard pallet assembly platform, and more specifically, the module allows the supply of different cardboard sheets to form different elements (sheets, inserts, complementary notches, reinforcements, etc.).

[0005] The forming module comprises a supply device capable of maintaining a continuous flow of pre-formed sheets, allowing for the loading and unloading of a new block of sheets without disrupting the process. Furthermore, the overall structure of the proposed forming module, with its corresponding supply device, allows for the use of different sheet geometries without requiring substantial modifications, enabling its use as a supply element for various stations or even for different types of products.

[0006] BACKGROUND OF THE INVENTION

[0007] In the cardboard industry, it is common practice to form cardboard items such as boxes or trays from pre-cut sheets. This means that the forming equipment only performs a series of folding, creasing, and gluing processes, or similar operations, using the necessary equipment (folders, folders, gluers, etc.) without the need for heavy and bulky dies.

[0008] Depending on the complexity, these processes can be carried out in one or more steps, with or without moving the semi-formed cardboard element between different stations. When supplying these cardboard sheets to the forming equipment, there are usually top-loading or bottom-loading machines. Both sheet supply options are conventional and are based on loading a series of aligned and stacked sheets onto the production line.

[0009] In the case of top-feed systems, the sheets are introduced into the production line by unloading them onto the line itself, for example, using gravity and a retention system that allows the supply of only one sheet of cardboard at a time. Another alternative is the use of robots or manipulators that, using suction cups or other gripping methods, can extract a sheet of cardboard from a lined stack and supply it independently to the process.

[0010] In the case of bottom-loading systems, a group of aligned and stacked cardboard sheets is usually introduced into a device capable of maintaining a constant supply stack height and, using elements prepared for this purpose, one sheet at a time is extracted to induce it, by means of pushers, in the corresponding process.

[0011] It should be noted that the type of load used in forming equipment like those commonly used is primarily limited by the type of flexible sheet material used for forming the components, as well as its size and weight. Generally, the flexible sheet material used is cardboard. The most common method for supplying preformed sheets is through top-loading systems, using manipulators that supply the sheets individually.

[0012] It should also be noted that, in the case of larger volume plates, the operation is usually semi-continuous, since once the supplied block of plates has been finished, a process of loading a new block of plates must be carried out for use in the forming of elements.

[0013] DESCRIPTION OF THE INVENTION

[0014] To overcome the aforementioned limitations, the invention has been devised, which consists of a forming module that allows for the uninterrupted supply of sheets (flexible material sheets) in a forming process installation. This module can be used with large and high-volume flexible sheet material sheets, enabling considerable versatility. Furthermore, it is compatible with different geometries, allowing the same module to be used without substantial modifications for various sheet geometries.

[0015] To this end, the module comprises four main zones: a loading zone, a flexible sheet material extraction zone, and a sheet supply zone for a forming process. It also includes a processing zone where the flexible sheet material is processed. The module of the present invention is designed to interconnect with other similar modules, with each module performing one or more different processes. A finished part from the first module is transferred to a second module, where the sheet processed in the second module is assembled with the part from the first module, forming an additive manufacturing process.However, this is beyond the scope of the invention, the essential part of this invention being the system for transferring sheets along the module, up to its processing point, and the system for transferring already processed sheets (for example, to another module).

[0016] The following describes each area of ​​the module and the operations that take place in each of them.

[0017] The first zone is a loading area where palletized sheets of flexible laminated material (preferably cardboard) are loaded, with a block of sheets placed on a pallet. In this zone, the module includes a series of motorized roller conveyors which move the pallet loaded with the sheets to the next zone of the module, which is an extraction zone.

[0018] The extraction zone also includes a series of roller conveyors. However, these conveyors are separate from the roller conveyors in the loading area, making it an independent zone. This is because once the pallet is positioned in this sheet extraction zone, it stops and is lifted above the rest of the roller conveyor surface. This sheet extraction zone has, at its top, a set of elements that allow the sheets to be extracted individually by lifting them above the sheet pallet. Once a handling device, which can be a suction cup manipulator, has lifted the sheet, retractable guides located on the sides extend, and the manipulator releases the sheet onto these guides.

[0019] Subsequently, a pusher transfers the sheet to the next zone. Once the sheet has been transferred to the supply zone and the space has been freed, the pallet is raised to its previous level, compensating for the removed sheet. The guides retract to allow a new sheet to pass through, and the procedure is repeated. This is repeated until the pallet is empty of sheets, at which point it is removed to allow a new load to pass through.

[0020] The sheet supply area for the process is located immediately after the extraction area. It consists of a carousel comprising two parallel, straight-guided conveyors separated by a certain distance, providing space to support a sheet of flexible sheet material and lower it to the supply area. The carousel also creates a stockpile of sheet material so that once the previous pallet is emptied, a number of sheets are stored and can continue to be supplied to the process until the new pallet is loaded and the supply of sheets for the process begins again from the loading area via the extraction area.

[0021] It is important to note that this supply area unloads the sheets onto scissor lift tables, from which a pusher then transfers the sheet of flexible laminate material (e.g., cardboard) to the processing area. The main function of this scissor lift table, besides being height-adjustable depending on the sheets, is to allow for the removal of a defective sheet without accessing the carousel mechanism, thus increasing operator safety.

[0022] Furthermore, the module is specially designed to be interconnected with other modules, supplying the processed part to another module for further operations, as well as assembling the finished parts with other parts, thus developing an additive manufacturing system.

[0023] The processing area is equipped with the necessary machinery to perform the corresponding process on the cardboard sheet, which can be assembled onto a piece from another module (for example, a piece that aligns with the piece from this module). It also includes a conveyor configured to move this piece to a second processing area and then to the next module in a forming installation, where the next module may or may not have a similar shape. In this way, conveyors are linked between forming areas, so that when a piece completes its movement on one conveyor between modules, the next conveyor can move the piece to the station where it is needed for further processing.

[0024] As described, this invention can be used for the handling and processing of any flexible sheet material. Among such flexible sheet materials, cardboard in sheet form is particularly noteworthy.

[0025] BRIEF DESCRIPTION OF THE FIGURES

[0026] Figure 1: shows an overview of the module where the different zones and the main elements of each of them are identified.

[0027] Figures 2A-B: A detail of the suction cup manipulator and retractable guides is shown, with a plate before loading onto the retractable guides and with that same plate already loaded onto the retractable guides respectively.

[0028] Figure 3: Shows a top plan view of two forming modules arranged one after the other in a pallet forming facility.

[0029] Figure 4: A new general plan of the module layout is shown without showing the loading entrance area where the pallet loaded with flexible sheet material is initially received.

[0030] Figure 5: A side elevation view of the module arrangement is shown without showing the loading entrance area where the pallet loaded with flexible material sheets is initially received.

[0031] Figures 6A-B: The operation of the carousel is shown and you can see how the plates are moved sequentially from a high position to a lower position, where they are pushed towards the next area of ​​the forming module.

[0032] The following is a list of the referenced elements:

[0033] C: forming module; Z1: loading inlet zone; Z2: extraction zone; Z3: supply zone; Z4: processing zone; Z4': second processing zone; P: plates; V: speed; 1: pallet; 2: motorized roller; 2': second motorized roller; 3: independent frame; 4: spindle; 5: chain; 6: centering mechanism; 7: suction cup manipulator; 8: retractable guides; 9: carousel; 10: scissor table; 11: carousel wheel; 12: carousel guide

[0034] DESCRIPTION OF AN EXAMPLE OF THE IMPERSONATION OF THE INVENTION

[0035] In a preferred embodiment of the invention, the forming module (C) comprises four zones: a first zone, a loading inlet zone (Z1), which is the receiving zone for the pallet load; a second zone, an extraction zone (Z2), where the sheets of flexible laminated material (preferably cardboard) from the pallet are extracted; a third zone, a supply zone (Z3), where these sheets are transferred to a device that allows for supplying and storing a certain number of pieces; and a fourth zone, a processing zone (Z4), in which the processing of the cardboard sheet is carried out (folding, gluing, creasing, etc.). Finally, once the processing of the cardboard sheet in the processing zone is complete, the module may include transfer systems for transferring the processed sheet to another module.

[0036] In the loading area (Z1), the load (the flexible material sheets) is placed on a pallet, and the pallet is moved using a base of motorized roller conveyors (2) that transport the loaded pallet (1) with sheets (P) of flexible sheet material (cardboard in a preferred example). Preferably, the forming module (C) is configured for use in installations for forming cardboard pallets.

[0037] The pallet (1) loaded with cardboard sheets (P) is moved by means of motorized rollers (2) to the extraction zone. This extraction zone is independent and has an independent frame (3) that also includes a second set of motorized rollers (2') and can be raised by means of a system of spindles (4) and chains (5) arranged at corners of the independent frame (3). This system of spindles (4) and chains (5) raises the pallet (1) loaded with sheets (P) to a suitable height, and at that point, a centering mechanism (6), located in the loading area (Z1), is used to ensure the correct positioning of the sheets (P).

[0038] Once in the correct position, a suction cup manipulator (7) in the extraction zone (Z2) extracts a sheet (P) (cardboard sheet) from the pallet (1). The suction cup manipulator (7) then descends and, using vacuum, extracts an individual sheet (P), raising it above the rest of the block of sheets (P). Subsequently, retractable guides (8), also located in the extraction zone (Z2), extend, creating a frame on which the sheet (P) can rest. Once the suction cup manipulator (7) releases the sheet (P) and it is positioned on the retractable guides (8), a pusher (not shown in the figures) moves the sheet (P) to a carousel (9) in the supply zone (Z3) via an upper section. When the sheet is fully housed in the carousel (9), the retractable guides (8) retract, allowing a new cardboard sheet (P) to be raised.

[0039] The carousel (9) comprises two carousel wheels (11) with parallel carousel guides (12) spaced a distance apart to ensure that the transferred sheet (P) is supported on both sides. Furthermore, the two carousel wheels (11) are synchronized so that the carousel guides (12) descend at the same speed (V) in parallel. In this way, two opposite sides of the sheet (P) are supported on one of the carousel wheels (11) at the same height and advance in parallel, keeping the sheet (P) horizontal. When the sheet (P) reaches a lower section of the supply area (Z3), it is placed on a scissor lift table (10) that allows for the rejection of the sheet (P) if it is defective.That is, the supply zone (Z3) comprises a scissor table (10) configured to support a plate (P) and with the ability to move vertically to modify its height and consequently the height at which the plate (P) is located in the supply zone (Z3).

[0040] If the sheet (P) is found to be valid (i.e., free of defects), it is transferred to the processing zone (Z4) by means of a pusher. The processing zone (Z4) comprises, in addition to at least one forming unit configured to perform the forming operation corresponding to the forming module (C), a conveyor configured to move the formed element or assembly to a second processing zone (Z4') from which it may or may not be sent to another forming module (C).

Claims

CLAIMS 1 Forming module for assembling elements and assemblies from flexible sheet material, characterized in that it comprises: - a loading entrance zone (Z1) configured to receive a plurality of plates (P) and comprising a transfer system; - an extraction zone (Z2) comprising at least one tray configured to receive at least one plate (P) from the loading inlet zone (Z1) and comprising at least a second transfer system and a transfer device; - a supply zone (Z3) comprising a dosing device for plates (P) extracted in the extraction zone (Z2) and said dosing device comprising at least one surface configured to receive said plates (P) and is configured to introduce the plates (P) into a processing zone (Z4); - the processing zone (Z4) configured to perform the forming operations corresponding to the forming module (C) and to move the plates (P) out of the forming module (C); and wherein the dosing device of the supply zone (Z3) is a carousel (9) comprising two parallel wheels spaced apart by a distance such that it allows the plates (P) to rest on them. 2.- Forming module according to claim 1 wherein the transfer system of the load entry zone (Z1) is a motorized roller transport system (2). 3.- Forming module according to any one of the preceding claims in which the second extraction zone transfer system (Z2) is a second motorized roller transport system (2'). 4.- Forming module according to any one of the preceding claims wherein the extraction zone transfer device (Z2) comprises a suction cup manipulator (7). 5.- Forming module according to any one of the preceding claims in which the extraction zone (Z2) comprises retractable guides (8) configured to extend, generating a frame intended to receive a plate (P). 6.- Forming module according to any one of the preceding claims in which the extraction zone (Z2) comprises a pusher.

7. A forming module according to any one of the preceding claims, wherein the supply zone (Z3) comprises a scissor table (10) configured to support a sheet (P) and capable of vertical displacement to modify its height and, consequently, the height at which the sheet (P) is located in the supply zone (Z3).

8. A forming module according to any one of the preceding claims, wherein the processing zone (Z4) comprises at least one forming unit configured to perform the forming operation corresponding to the forming module (C) and a conveyor configured to move a formed element or assembly from the sheet (P) to a second processing zone (Z4').

Images