A system that automatically empties and stacks bottled product boxes

Abstract

The present invention relates to an integrated system and method for robotically decasing bottles or cans in boxes / cases and folding and stacking empty cartons. The system delivers the empty carton to the carton folding station (4) on the multi-axis robot (1 ) with a gripper (2) suitable for aligning and gripping from the side surfaces. At the station, the carton is fixed from below by vacuum (4.5.2); folded by side pushers / folding elements (4.5.1,4.5.3, 4.5.4); lowered to the stacking plane by the carrying axis (4.4) and the pressing axis (4.2) prevents the folded carton from reopening by applying pressure from above. Sensors (2.6) and the control unit adapt the vacuum / pressure thresholds and timing to the carton size during format changes, reducing the risk of impact on sensitive products and enabling product changeover without line stoppage. The system works integrated with production lines with its conveyor infrastructure and pallet exit.

Description

[0001] A SYSTEM THAT AUTOMATICALLY EMPTIES AND STACKS BOTTLED PRODUCT BOXES

[0002] Field of the Invention

[0003] The present invention relates to a box emptying and stacking system.

[0004] The present invention relates to a system for automatically emptying boxes of empty products (bottles or cans) and stacking these carton boxes, particularly in the fields of food, medicine, chemistry, cosmetics, logistics, automotive sub-industry and warehouse automation.

[0005] State of the Art

[0006] Today, the automatic emptying of boxes or crates containing empty products (bottles, cans, etc.) and the stacking of empty boxes / crates is a process widely used in the food, beverage, and pharmaceutical industries, as well as in the food, pharmaceutical, chemical, cosmetics, logistics, automotive supply, and warehouse automation industries. Existing systems developed for this purpose generally consist of two main parts: a decasing unit and a stacking unit.

[0007] Known decasing systems work on the principle of feeding boxes or crates via a conveyor belt, fixing them in a certain position and removing the products inside. Various methods are used to remove products from boxes or crates. These include vacuum grippers that grip products from the top, mechanical gripper systems that grip products from the body or neck, magnetic grippers for metal packaged products, and inverting systems that allow the products to be released by turning the box or case upside down.

[0008] For the stacking of empty boxes or crates, solutions such as side-tilting stacking, vertical stacking, robotic palletizing and automatic folding and stacking systems for foldable boxes are applied. These systems are integrated into the production line and have the ability to operate continuously and at high speed. Additionally, auxiliary technologies such as image processing systems and servo-controlled axis mechanisms are used to accurately detect and move products. Although current systems provide advantages in terms of high speed, low labor cost and hygiene, they have some technical limitations. When processing products of different sizes and shapes, system settings may need to be changed, this may cause the production line to stop. Gripper systems with insufficient adaptability make it difficult to process more than one product type on the same line. Additionally, there is a risk of damage to fragile glass bottles or thin metal cans at high speed or by incorrect gripping. In inversion methods, problems such as crashing and cracking may occur.

[0009] In addition, these systems generally take up a large area on the line and can be restrictive in terms of layout, especially when stacking and palletizing units are used together. High energy consuming components such as vacuum pumps and compressed air systems can increase operating costs. Wear on mechanical parts, sealing problems in vacuum systems and alignment requirements are among the factors that increase the need for maintenance.

[0010] The invention titled US 2,758,731 A “Case unloader”, which is also included in the current art, relates to a classical “case unloader” machine that enables the separation of upright bottles from compartmented cases (partitioned cases). It is based on the principle of grasping the bottles, separating them from the case and delivering them in a single line with tandem belt / guide arrangements.

[0011] Again, the invention numbered US 2013 / 0247524 A1 , titled “Carton decasing system”, relates to a system for taking crates containing carton or stacks of carton into the work line, inverting the crates and separating the carton / blank stacks from the crate (decasing). It covers the steps of in-line feeding of cartons after decasing and preparation for stacking.

[0012] The present invention, numbered US 5,426,921 A, titled “Carton stacking method and apparatus” relates to a method and device for transporting cartons coming out of the packaging line one by one, orienting them to a stacking plane and stacking them in an orderly manner with a robotic gripper / placer. It comprises mechanisms that control both orientation and stack order.

[0013] Object of the Invention One object of the present invention is to eliminate the disadvantages in the known state of the art and to provide advantages in terms of high speed, low labor cost and hygiene. The production line enables the processing of products of different sizes and shapes without stopping. Additionally, there is a risk of damage to fragile glass bottles or thin metal cans at high speed or by incorrect gripping. It does not contain problems such as crashing and cracking during the inversion process.

[0014] The system of the present invention provides an integrated system that combines the decasing + folding + stacking steps of cartons in a single flow, so that the production line can process products of different sizes, shapes, materials and weights without stopping, and format changes can be made without stopping the line.

[0015] The system can vary depending on product / box size, dimension and structure, such as single carton structure or double carton structure. Accordingly, different materials such as steel, aluminum, composite, plastic, 3D printed parts, etc. can be used in the system.

[0016] Description of Drawings

[0017] Figure 1 is the general perspective view of the system of the present invention,

[0018] Figure 2 is the perspective view of the robot belonging to the system of the present invention,

[0019] Figure 3 is the perspective view of the vacuum holder / gripper unit of the system of the present invention,

[0020] Figure 4a is the perspective view of the product holder of the system of the present invention, aligning the product to be held,

[0021] Figure 4b is the perspective view of the Product holder arms of the system of the present invention,

[0022] Figure 5 is the perspective view of the carton folding station of the system of the present invention,

[0023] Figure 6a is the perspective view of the carton folding station of the system of the present invention with the left and right walls in the up position (painted yellow), 2 folding elements (4.5.4) in the up position, 2 folding elements (4.5.3) in the back position, and 1 cylinder (4.5.1 ) in the back position,

[0024] Figure 6b shows the perspective view of the carton carrying axis of the carton folding station of the system of the present invention, Figure 7 is the perspective view of the robot of the system of the present invention, bringing the carton with the bottles spilled and leaving it at the station,

[0025] Figure 8 is the perspective view of the vacuumed cartons being pulled down to the down position after the robot of the system of the present invention releases the carton, Figure 9 is the perspective view of the cylinder group (4.4) and pistons (4.4.3) of the system of the present invention,

[0026] Figure 10 is the perspective view of the stacking of the folded cartons via the axis with the system of the present invention,

[0027] Figure 11 is the perspective view of the system of the present invention, where the carton pressing axis is positioned on the folded cartons to prevent the cartons from opening again.

[0028] Figure 12 is the perspective view of the carrier axis of the system of the present invention returning to its initial upward position. Description of the Reference Numbers

[0029] Detailed Description of the Invention

[0030] The invention is a system for automatically emptying boxes (8) of empty products (bottles or cans) and stacking these carton boxes (8) in the fields of food, medicine, chemistry, cosmetics, logistics, automotive sub-industry and warehouse automation, comprising a multi-axis, programmable robot (1 ) having a robot chassis (1.1 ) that secures the robot arm (1.2); a gripper unit (2) mounted on the end of the robot arm (1.2) that grips the products (bottles or cans) (8) from the side or bottom surface and carries them; and a carton folding station (4) where the robot (1) leaves the emptied carton for folding after pouring the bottles or cans (8) (figure 1 ). The system which is the subject of the invention seen in Figure 1 ; comprising a multiaxis, programmable robot (1 ) having a robot chassis (1.1 ) that secures the robot arm (1 .2); a gripper unit (2) mounted on the end of the robot arm (1 .2) that grips the products carton (8) from the side or bottom surface and carries them; and a carton folding station (4) where the robot (1 ) leaves the emptied carton (8) for folding after pouring the bottles or cans (8)

[0031] The industrial robot (1 ) shown in Figure 2 is a multi-axis, programmable robotic arm. Designed to automatically perform palletizing, handling or placement tasks. It is a multiaxis, programmable mechanical carrying arm. This robot (1 ) is configured to pick up products (8) from one location and place them in another location. It can usually have a 4 to 6-axis structure. It can be hydraulic, pneumatic or electric driven. Various holders can be integrated into the tip (vacuum, mechanical, magnetic, etc.).

[0032] Robot chassis (1.1 ), seen in Figure 2, is the mechanical base and flange structure that enables the fixation of the robot arm (1 .2). It may be fixed to the floor or to a platform. It must have the strength appropriate to the moment and load carrying capacity of the robot (1 ). Control cables and power supplies can also pass through this section.

[0033] Vacuum gripper unit (2) seen in Figure 3, is an apparatus mounted on the end of the robot arm (1 .2) that carries the products (bottles or cans) (8) by gripping them from the side or bottom surface with vacuum. Robot connection flange (2.1 ) has a replaceable structure specific to different types of robot wrists (Quick tool changer). It ensures that the products (8) are lifted and moved precisely. It allows the products (8) to be lifted and placed precisely. It is the gripper system that is connected to the end of the robot arm (1 .2) and used to carry the products (8). The gripper system can be equipped with pneumatic fingers as well as vacuum suction cups. It may vary depending on the shape, sensitivity and weight of the products (8). Adaptive end elements for different product types can be integrated into the same holder. As the holder / gripper unit (2); alternatives such as vacuum, mechanical, magnetic or combination holders can be used.

[0034] The left wall (2.2), right wall (2.3) and front wall (2.4) seen in Figure 4a go to the back position and go to the open position. The product holder (2) aligns the product to be held (8). Vacuums are opened from the vacuum pads (2.2.2, 2.3.2) on the left and right walls (2.2, 2.3). In Figure 4b, the front wall (2.4), the right wall and the left wall (2.2, 2.3) move to the forward position, respectively. In Figure 4b; the pneumatically forward moving arms (2.2.1 , 2.3.1 , 2.4.1 ) move forward until the line type pneumatically regulated air (air supply adjustable between 1 -10 bar pressure) connected to the arms (2.2.1 , 2.3.1 , 2.4.1 ) completes the strokes. The products (8) are retained.

[0035] The empty pallet feeding conveyor (3) seen in Figure 1 is a lifting system that adjusts the position of the pallet vertically. It can be hydraulic, ball screw, roller, chain or chain driven. The empty pallet feeding conveyor (3) feeds empty pallets to the carton folding station (4).

[0036] The carton folding station (4) seen in Figure 5 is the station where the robot (1 ) leaves the carton (8) to be folded after pouring the bottles inside the carton (8). If there is no pallet at the beginning, the empty pallet is fed from the empty pallet feeding conveyor (3) to the carton folding station (4) via the conveyor (10) integrated into the carton folding station.

[0037] As seen in Figure 6a, the left and right walls (4.5) are in the up position (painted yellow). 2 folding elements (4.5.4) are in the up position, 2 folding elements (4.5.3) are in the back position, 1 cylinder (4.5.1 ) is waiting in the back position. There is a vacuum group (4.5.2) that vacuums the carton left by the robot (1 ) from below and holds it to prevent it from slipping before folding. Figure 9 shows the perspective view of the carton carrying axis (4.4).

[0038] As can be seen in Figure 7, the robot (1 ) brings the carton (8) with the bottles spilled, leaves it at the station and leaves. As can be seen in Figure 8, after the robot (1 ) releases the carton, the vacuumed cartons are pulled down to the down position. (Folding element (4.5.4) goes to down position). Then the cylinder group (4.5.1 ) pushes the carton from the side surface. In Figure 9, the cylinder group (4.4.2) inside the cylinder group (4.4) located on the carton transport axis is waiting in the forward position. After the group cylinders (4.5.1 ) move forward, the group cylinders (4.4.1 ) move to the forward position. Temporary holding pistons (4.4.3) on the transport axis apply preliminary pressure to hold the carton in place before and during lowering; this pressure is not intended to give permanent shape.

[0039] As can be seen in Figure 10, the left and right wall (4.5) group vacuums are closed. The pistons (4.5.4) go down. The pistons (4.5.3) move to the forward position. As can be seen in Figure 10, the folded carton is stacked via the axis (4.2). It moves downwards with an electric motor, pneumatic axis or any drive group (4.3 drive group is provided for 4.2, 4.6 drive group is provided for 4.4). Each axis is driven by a dedicated drive group: the pressing axis (4.2) by drive group (4.3), and the carrying axis (4.4) by drive group (4.6). Pneumatic, hydraulic, electric or other drive types can also be integrated into the system as drive systems.

[0040] As can be seen in Figure 11 , the carton pressing axis (4.2) is positioned on top of the folded cartons to prevent the cartons from opening again. The cylinders (4.2.2) move to the forward position. After the cylinder group (4.4) lowers the folded carton to the down position, the carrying axis (4.2) positions itself on the folded cartons, opens and presses the arms (4.2.2). As can be seen in Figure 12, the carrying axis (4.4) returns to its up starting position.

[0041] The carton carrying axis (4.4) holds the folded carton left by the robot (1 ) from above and carries it downwards. The other carton axis (4.2) is positioned on the carton carried by the carton carrying axis (4.4) and puts pressure on the carton to prevent it from opening again.

[0042] Product feeding conveyor (9) is the conveying line where the products (8) to be carried by the robot (1 ) enter. The products (8) are sorted here and transported to the conveyor station (11 ) to be picked up by the robot (1 ). After the unloading of the products (8) taken by the robot (1 ) in the conveyor (11 ) line is completed, the empty pallet is transferred from the conveyor (11 ) to the palletizing station (5).

[0043] Empty pallet feeding conveyor (3), also seen in Figure 1 ; the empty pallet is transferred from the feeding conveyor (3) to the pallet conveyor (10) integrated into the carton folding station (4). The pallet filled with folded cartons at the carton folding station (4) is transferred to the pallet conveyor (10) integrated into the carton folding station (4) and to the carton output conveyor (6).

Claims

CLAIMS1. A method for automatically emptying boxes (8) of empty products (bottles or cans) and stacking these carton boxes, characterized by comprising the process steps of; lifting, transporting and emptying of products (bottles or cans) (8) gently by grasping or holding from the side or bottom surface with vacuum with a robot (1 ) and a gripper unit (2) mounted at the end of the robot arm (1.2) folding and stacking the carton (8) in a carton folding station (4) after the robot (1 ) has poured the bottles inside the carton.

2. A method according to claim 1 , characterized in that; the left and right walls (4.5) are in the up position, 2 folding elements (4.5.4) are in the up position, 2 folding elements (4.5.3) are in the back position, 1 cylinder (4.5.1 ) is in the back position.

3. A method according to claim 2, characterized by comprising bringing the carton (8) with the bottles poured out by the robot (1 ), robot’s leaving the same at the station and going back.

4. A method according to claim 3, characterized by comprising; pulling the vacuumed cartons (8) to the down position (Folding element (4.5.4) goes to the down position) after the robot (1 ) releases the carton (8), then the cylinder group (4.5.1 ) pushing the carton from the side surface, the cylinder group (4.4.2) is being kept in the forward position within the cylinder group (4.4), moving the cylinders (4.4.1 ) to the forward position after the group cylinders (4.5.1 ) move forward, temporary holding pistons (4.4.3) applying pre-press (preliminary pressing pressure) to prevent falling / re-opening of the folding cartons (8) before and during lowering.

5. A method according to claim 4, characterized by comprising closing the left and right wall (4.5) group vacuums, moving the pistons (4.5.4) down, moving the pistons (4.5.3) to the forward position (Figure 6a), and stacking the folded carton via the axis (Figure 10).

6. A method according to claim 5, characterized by comprising positioning the carton pressing axis on the folded cartons to prevent the cartons from openingagain, opening and pressing the arms, and returning the carrier axis to its upward starting position.

7. A method according to claim 1 , characterized by comprising positioning the carton pressing axis (4.2) on the folded cartons to prevent the cartons from opening again, cylinders (4.2.2) moving to forward position, positioning the transport axis (4.2) on the folded cartons after the cylinder group (4.4) lowers the folded carton to the down position, opening and pressing the arms (4.2.2), returning the carrier axis (4.4) to its up starting position.

8. A method according to claim 7, characterized by comprising the carton carrying axis (4.4) holding the folded carton left by the robot (1 ) from above and carrying the same downwards, while the other carton axis (4.2) positioning itself on the carton brought by the carton carrying axis (4.4) and putting pressure on the same to prevent the carton from opening again.

9. A system for automatically emptying boxes (8) of empty products (bottles or cans) and stacking these carton boxes (8), characterized by comprising;- a multi-axis, programmable robot (1 ) containing a robot chassis (1.1 ) that secures the robot arm (1 .2),- a gripper unit (2), which is mounted on the end of the robot arm (1.2), allows the products (bottles or boxes) (8) to be lifted, transported and discharged precisely by grasping them from the side or bottom surface with vacuum or by holding them.

10. A system according to claim 9, characterized by a robot chassis (1.1 ) which comprises a mechanical base and flange (2.1 ) structure with an interchangeable structure specific to different types of robot wrists that enable the fixation of the said robot arm (1 .2).

11. A system according to claim 9, characterized by a holding unit (2) that works by vacuuming with vacuum suction cups.

12. A system according to claim 9, characterized by a holding unit (2) that works by holding with pneumatic fingers, such as mechanical, magnetic, or combination holders.

13. A system according to claim 9, characterized by a holding unit (2) consisting of the left wall (2.2), right wall (2.3), front wall (2.4), vacuum pads (2.2.2, 2.3.2), arms (2.2.1 , 2.3.1 , 2.4.1 ) in the form of pistons connected to the walls (2.2, 2.3,2.4) that move forward pneumatically, and line type pneumatically regulated air (air supply adjustable between 1-10 bar pressure) connected to the arms, to hold the product (8).

14. A system according to claim 9, characterized by the empty pallet feeding conveyor (3) that adjusts the position of the pallet vertically and provides lifting.

15. A system according to claim 14, characterized byhydraulic, ball screw, roller, chain or chain-driven empty pallet feeding conveyor (3).

16. A system according to claim 15, characterized by feeding conveyor (3) that allows the robot (1 ) to work in a fixed position, providing a height suitable for product (8) placement in layers.

17. A system according to claim 9, characterized by carton folding station (4) where the robot (1 ) leaves the emptied carton (8) to be folded after pouring the bottles inside the carton (8).

18. A system according to claim 17, characterized by the carton folding station (4) which comprises the vacuum group (4.5.2) that vacuums the carton left by the robot (1 ) from the bottom and holds it to prevent it from slipping before folding, the left and right walls (4.5) to fold the emptied carton (8), 2 folding elements (4.5.4), 2 folding elements (4.5.3), 1 cylinder (4.5.1 ), green vacuum pads (2.2.2, 2.3.2) parts (figure 4a), temporary holding pistons (4.4.3) and the pre-press (preliminary pressing pressure) application before and during lowering.

19. A system according to claim 18, characterized by the carton folding station (4) comprising the carton pressing axis (4.2) which is positioned on the folded cartons to prevent them from opening again, the arms (4.2.1 ) which are opened and pressed, and the carrying axis (4.4) which returns to its starting position after compression.

20. A system according to claim 9, characterized by comprising palletizing station main chassis (5), which is the steel structure that supports the entire system.

21. A system according to claim 9, characterized by comprising the product feeding conveyor (9) serving as the entry line for the products (8) to be carried by the robot (1 ) to be listed and prepared for collection.

22. A system according to claim 9, characterized by comprising a product feeding conveyor (9) as the input line in the system, with pallets stacked with products (8) on them, and a carton output conveyor (6) as the output line.

23. A system according to claim 9, characterized by comprising a pallet conveyor (10) integrated into the cardboard folding station (4).

24. A system according to claim 9, characterized by a system that can be manufactured from steel, aluminum, composite, plastic, and 3D printed parts.

25. A system according to claim 9, characterized in that; Electric axis (Servo motor, asynchronous motor etc. drive element) is driven by separate drive group for each axis; carton pressing axis drive group (4.3) is driven by carton pressing axis (4.2), carton carrying axis drive group (4.6) is driven by carton transport axis (4.4).

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