A system and method for removing bottles from cardboard boxes

Abstract

The invention is a system and method in which the boxes (3.1) containing bottle type products (3.2) are taken from at least one product group feeding conveyor (5) and the products (3.2) inside are automatically discharged onto at least one product exit conveyor (6). In the invention, the product group of at least one gripper unit (2) is brought to the feeding conveyor (5) and approached to at least one box (3.1) by at least one robot arm (1.1) belonging to a robot (1), the boxes (3.1) are held by vacuum from at least one surface with the said gripping unit (2), and after the boxes (3.1) are held, they are moved linearly and taken into the gripping unit (2), with the gripper unit (2), the boxes (3.1) are turned upside down, the gripper unit (2) is moved between the feeding conveyor (5) and the product exit conveyor (6) with the robot (1 ) and the robot arm (1.1), and the products (3.2) in the inverted boxes (3.1) are left on the product exit conveyor (6).

Description

[0001] A SYSTEM AND METHOD FOR REMOVING BOTTLES FROM CARDBOARD BOXES

[0002] Technical Field

[0003] The invention relates to box emptying systems and methods.

[0004] The invention relates to a system and method that enables automatic removal of bottles from cardboard boxes, particularly in the fields of food, beverage, pharmaceutical, chemical, cosmetic, logistics, automotive sub-industry and warehouse automation.

[0005] State of Art

[0006] Today, the process of automatically removing products from cardboard boxes or cases containing bottles is widely used in the fields of food, beverage, pharmaceutical, chemical, cosmetics, logistics, automotive sub-industry and warehouse automation. Existing systems developed for this purpose generally consist of a decasing unit and conveyor structures that enable the products to be separated and fed into the line.

[0007] Decasing systems, which are known, work on the principle of feeding boxes or cases via a conveyor belt, fixing them in a certain position and removing the products inside. Various methods are used to separate products from boxes or cases. These include vacuum grippers that grip products from the top, mechanical gripper systems that grip products by the body or neck, magnetic grippers for metal-packaged products, and inverting systems that flip boxes over to release their contents.

[0008] Although current systems are advantageous in terms of high speed, low labor costs and integration into production lines, they have some limitations. When processing products of different sizes and shapes, system settings may need to be changed, which may cause line stoppages. Fragile glass bottles or thin plastic bottles can be damaged by high speed or wrong grip. In systems that operate using the inversion method, problems such as impact, cracking and tumbling may occur. Additionally, these systems generally cover large areas and contain components with high energy consumption.

[0009] The invention titled US 2,758,731 A “Case unloader”, which is also included in the present art, is a classical case unloader machine for separating upright bottles from compartmented cases and separates the bottles from the case with tandem belt / guide arrangements and delivers them in a single line.

[0010] Besides that, the invention titled “Carton decasing system”, numbered US 2013 / 0247524 A1 , is for the separation (decasing) of products by turning cardboard boxes upside down and includes the processes of taking the boxes into the line and emptying them.

[0011] The invention, numbered US 5,426,921 A and titled “Carton stacking method and apparatus”, is a method and device for carrying and stacking boxes or cartons and does not directly include the process of removing bottles from the boxes.

[0012] Object of the Invention

[0013] An object of the invention, in order to eliminate the disadvantages in the state of the art, is to ensure that cardboard boxes containing bottles of different sizes, shapes and materials are automatically emptied without stopping the production line and without damaging the products.

[0014] Another object is to prevent damage to fragile products such as glass or plastic when removing bottles from boxes and to eliminate the risks of impact and tumbling encountered in inverted methods.

[0015] The system, which is the subject of the invention, grips the bottles inside the cardboard boxes by vacuuming them from the front and bottom surfaces with robotic gripper groups working synchronously on the upper and lower axes, releases the products to the conveyor line in a controlled manner and directs the emptied cartons to the folding station, making them ready for the next process. The invention thus offers an integrated solution that enables both the safe and rapid separation of bottles from boxes and the orderly folding and stacking of empty boxes in a single flow.

[0016] Description of Figures

[0017] Figure 1 is a general perspective view of the system, which is the subject of the invention.

[0018] Figure 2 is a perspective view of the robot, which is the subject of the system.

[0019] Figure 3 is a perspective view of the gripper unit, which is the subject of the invention.

[0020] Figure 3A is the view of the upper axis group in the gripper unit in the forward position and the lower axis group in the backward position,

[0021] Figure 3B is the view of the upper axis group in the gripper unit, held by the vacuum pads from the front surface of the product group,

[0022] Figure 3C is the view where the upper axis group of the gripper unit is returned to the back position,

[0023] Figure 3D is a view of the gripper unit with the lower axis group held by vacuum pads on the bottom surface of the product group,

[0024] Figure 3E is a view of the gripper unit being rotated,

[0025] Figure 3F is a view of the gripper unit being rotated 180°,

[0026] Figure 3G is the view where the gripper unit upper axis and lower axis group are moved to the forward position,

[0027] Figure 3H is the view where the gripper unit moves up and drops the products in the box onto the product exit conveyor, Figure 31 is the view where the upper axis and lower axis groups of the gripper unit that releases the products are moved to the back position, Figure 3J is the view where the lower axis group of the gripper unit stops vacuuming the box bottom surface,

[0028] Figure 3K is a view of the gripper unit with the upper axis positioned forward, leaving the front surface of the box and depositing it into the folding station,

[0029] Figure 3L is a perspective view of the gripping jaws on the gripper unit,

[0030] Figure 3M is a perspective view of the upper axis group on the gripper unit. Description of Reference Numbers

[0031] Detailed Description of the Invention The invention relates to a system configured to automatically empty cardboard boxes (3.1 ) containing products such as bottles (3.2) and to direct the emptied boxes (3.1 ) to a box folding station (4) for folding in the fields of food, beverages, pharmaceuticals, chemicals, cosmetics, logistics, automotive sub-industry and warehouse automation. The system generally consists of the following components: a gripper unit (2) placed on at least one robot arm (1.1 ); product groups (3) that can be held, moved and rotated by the gripper unit (2); a box folding station (4) configured to fold the boxes (3.1 ) after the products (3.2) are removed; at least one product group feeding conveyor (5) that feeds the product group (3) to the gripper unit (2); and at least one product exit conveyor (6) to which the removed products (3.2) are directed (Figure 1 ).

[0032] The robot (1 ) shown in Figure 2 is a multi-axis, programmable handling device. The robot arm (1.1 ) is configured to operate in various positions within the system. The robot base (1.2) is the structural section that secures the robot (1 ) and provides its balance. The gripper unit (2), shown in Figure 3, is mounted on the robot arm (1.1 ) and is responsible for carrying boxes (3.1 ) containing products (3.2) by vacuuming their front and bottom surfaces. The gripper unit (2) consists of the body block (2.1 ), length adjustment mechanism (2.2), gripping jaws (2.3), cable duct (2.4), lower axis group (2.5), and upper axis group (2.6). The body block (2.1 ) is the main structure that houses all mechanical elements. The gripping jaws (2.3) contact the box (3.1 ), while the jaw indexing pin (2.3.1 ) and jaw locking pin (2.3.2) position and secure the jaws. The upper axis group (2.6) and the lower axis group (2.5) are configured to work synchronously, removing the products (3.2) in a controlled manner and transporting the boxes (3.1 ) in a stable manner.

[0033] In the invention, there is a body block (2.1 ) in the gripper unit (2). Said body block (2.1 ) refers to the main carrier structure on which all mechanical and moving parts of the gripper unit (2) are placed. This structure, connected to the robot arm (1.1 ), ensures the overall rigidity and integrity of the gripper unit (2). All sub-components such as the upper axis group (2.6), lower axis group (2.5), gripping jaws (2.3), length adjustment mechanism (2.2) and cable duct (2.4) are mounted on this body block (2.1 ).

[0034] In the invention, there is a height adjustment mechanism (2.2) in the gripper unit (2). The height adjustment mechanism (2.2) is the guiding element that allows the gripper unit (2) to move in the C and D directions on the vertical axis to adapt to boxes (3.1 ) and product groups (3) of different heights. Thanks to this structure that provides linear movement according to the height of the box (3.1 ), the system can adapt to boxes (3.1 ) of different sizes and appropriate gripping ability can be provided according to the box (3.1 ) position.

[0035] In the invention, there are gripping jaws (2.3) in the gripper unit (2). The gripping jaws (2.3) are movable parts that can be adjusted to adapt to the size variability of the boxes (3.1 ) in the product group (3). The gripper jaws enable the height adjustment mechanism (2.2) to be adjusted and held appropriately to different heights. There is a jaw indexing pin (2.3.1 ) and a jaw locking pin (2.3.2) on the gripping jaws (2.3). The jaw indexing pin (2.3.1 ) adjusts the height of the jaw, while the jaw locking pin (2.3.2) provides stability during transport by fixing this position. (Figure 3L) The gripper unit (2) mentioned in the invention includes a cable duct (2.4). Said cable duct (2.4) is the duct that ensures the orderly transport and protection of cables, hoses and other transmission elements that reach the moving parts of the gripper unit (2). The connections for vacuum pads, sensors, and pneumatic equipment are routed through this duct, ensuring an orderly cabling system within the gripper unit (2). This facilitates system maintenance and continuity.

[0036] In the invention, there is a lower axis group (2.5) in the gripper unit (2). Said lower axis group (2.5) ensures that the box (3.1 ) placed within the gripper unit (2) is supported and carried by being held by vacuum from its lower surface. The said lower axis group (2.5) comprises a lower axis drive shaft (2.5.1 ), two lower axis linear piston bearings (2.5.2), a lower axis base plate (2.5.3), a lower axis drive motor (2.5.4), at least one lower axis vacuum pad (2.5.5), a vacuum pad cylinder (2.5.6) and a support part (2.5.7). The lower axis vacuum pads (2.5.5) provide grip by applying vacuum from the bottom surface of the box (3.1 ). The lower axis vacuum pads (2.5.5) are moved in the C and D directions by the vacuum pad cylinder (2.5.6). The lower axis drive motor (2.5.4) and drive shaft (2.5.1 ) provide the forward and backward movement of the entire lower axis group (2.5) in directions A and B. The support part (2.5.7) undertakes the bearing and guiding of the system.

[0037] In the invention, there is an upper axis group (2.6) in the gripper unit (2). The said upper axis group (2.6) is the moving mechanism that allows the boxes (3.1 ) to be transported by being held by the vacuum from their front surface and to be taken into or out of the gripper unit (2) by moving linearly back and forth in the A and B directions. This structure comprises an upper axis drive shaft (2.6.1 ), two upper axis linear piston bearings (2.6.2) and at least one upper axis vacuum pad (2.6.3), an upper axis drive motor (2.6.4). The vacuum pads (2.6.3) adhere to the front surface of the box (3.1 ) and allow the gripper unit (2) to carry the box (3.1 ). The upper axis group (2.6) works synchronously with the lower axis group (2.5) to enable the box (3.1 ) to be held and rotated in a balanced manner. (Figure 3M)

[0038] As seen in Figure 3A, in the invention, firstly the lower axis group (2.5) of the gripper unit (2) is located in the back position in the A direction, and the vacuum pad cylinder (2.5.6) is located in the down position in the D direction. At the same time, the upper axis group (2.6) is positioned forward in direction B. This positioning represents the preparatory position of the gripper unit (2) before approaching the product group (3).

[0039] In the next step, shown in Figure 3B, the gripper unit (2) approaches the products (3.2) that constitute the product group (3) and are located in the cardboard boxes (3.1 ) by means of the robot arm (1.1 ). The upper axis vacuum pads (2.6.3) located in the upper axis group (2.6) are activated and adhered to the front surface of the box (3.1 ).

[0040] In the next step, shown in Figure 3C, the product group (3) is taken into the gripper unit (2) with the backward movement of the upper axis group (2.6) in direction A. The box (3.1 ) continues to be held by vacuum from its front surface.

[0041] In the next step seen in Figure 3D, the vacuum pad cylinder (2.5.6) located in the lower axis group (2.5) moves upwards in the C direction and brings the lower axis vacuum pads (2.5.5) located on the lower axis base plate (2.5.3) into contact with the lower surface of the box (3.1 ). At this stage, vacuum is also applied from the bottom surface and the box (3.1 ) is held in two-way vacuum from both the front surface (with the upper axis vacuum pads (2.6.3)) and the bottom surface (with the lower axis vacuum pads (2.5.5)).

[0042] In the next step, shown in Figure 3E, the gripper unit (2), which holds the product group (3) from its front and bottom surfaces with vacuum, is positioned so that it is prepared for the rotation movement by the robot arm (1.1 ). This position represents the intermediate position before the inversion of the box (3.1 ).

[0043] In the next step shown in Figure 3F, the gripper head of the gripper unit (2) is rotated 180° by means of the robot arm (1.1 ). As a result of this movement, the box (3.1 ) is turned upside down and the products (3.2) inside the box (3.1 ) become ready to be discharged by the effect of gravity.

[0044] In the next step, shown in Figure 3G, the lower axis group (2.5) and the upper axis group (2.6) move forward synchronously in direction B. Thanks to this movement, the box (3.1 ) and the products inside (3.2) are deposited on the product exit conveyor (6) by the effect of gravity. In the next step, shown in Figure 3H, the gripper unit (2) is moved upwards in direction C over the product exit conveyor (6). At this stage, the box (3.1 ) is still held in the gripper unit (2) while the products (3.2) remain on the conveyor.

[0045] In the next step shown in Figure 3I, after the products (3.2) are deposited on the product exit conveyor (6), the lower axis group (2.5) and the upper axis group (2.6) of the gripper unit (2) are synchronously pulled back to the position in direction A. Thus, the empty box (3.1 ) is taken into the gripper unit (2).

[0046] In the next step, shown in Figure 3J, the robot arm (1.1 ) directs the gripper unit (2) to one of the box folding stations (4) defined in the system. At this time, the vacuum pad cylinder (2.5.6) moves down in the D direction, the lower axis vacuum pads (2.5.5) stop vacuuming from the bottom surface of the box (3.1 ).

[0047] In the next step, shown in Figure 3K, the upper axis group (2.6) moves forward in direction B and pushes the box (3.1 ) out of the gripper unit (2). In this position, the upper axis vacuum pads (2.6.3) of the upper axis group (2.6) release the vacuum. Thus, the box (3.1 ) is released to the box folding station (4). The box (3.1 ) is folded at the box folding station (4) and transformed into the folded box (3.3) form.

[0048] The robot (1 ) included in the invention is responsible for directing the gripper unit (2) to the product group feeding conveyor (5), product exit conveyor (6) and box folding station (4). The gripper unit (2) holds on to the box (3.1 ) in the product group (3) by vacuuming at least one surface, gripping the box (3.1 ) and taking it into the gripper unit (2). The lower and upper axis groups (2.5, 2.6) work synchronously, ensuring that the box (3.1 ) is held by double-sided vacuum from both the front and bottom surfaces. By rotating the gripper unit (2) 180° by means of the robot arm (1.1 ), the box (3.1 ) is turned upside down and the products inside (3.2) are transferred to the product exit conveyor (6) by the effect of gravity. After unloading the products (3.2), the robot (1 ) guides the gripper unit (2) to the box folding station (4), where the upper axis group (2.6) pushes the box (3.1 ) forward while the vacuum is released and the box (3.1 ) is deposited on the folding station (4). In this way, the processes of taking the box (3.1 ), unloading the products (3.2) and delivering the empty box (3.1 ) to the box folding station (4) are carried out automatically and in an integrated manner. Thanks to all these steps, the process of emptying bottle type products (3.2) in the box (3.1 ) is managed in an automated manner without the need for human intervention.

Claims

CLAIMS1. The invention is a method in which the boxes (3.1 ) containing bottle type products (3.2) are taken from at least one product group feeding conveyor (5) and the products (3.2) inside are automatically discharged onto at least one product exit conveyor (6), wherein; it comprises the following process steps:• at least one robot arm (1.1 ) and at least one gripper unit (2) of a robot (1 ) are brought to the product group feeding conveyor (5) and brought closer to at least one box (3.1 ),• holding the boxes (3.1 ) by vacuum on at least one surface using the mentioned gripper unit (2).• after holding the boxes (3.1 ), they are moved linearly and placed into the gripper unit (2),• turning the gripper unit (2) and the boxes (3.1 ) so that they are upside down,• moving the gripper unit (2) with the mentioned robot (1 ) and robot arm (1.1 ) between the feeding conveyor (5) and the product exit conveyor (6),• placing the products (3.2) in the inverted boxes (3.1 ) on the product exit conveyor (6).

2. A method according to claim 1 , wherein;• an upper axis group (2.6) located in the gripper unit (2) with the ability to move backward in direction A and forward in direction B is positioned in the forward position in direction B.• a lower axis group (2.5) located in the gripper unit (2) with the ability to move backward in direction A and forward in direction B is positioned in the backward position in direction A.• a robot arm (1.1 ) moves the gripper unit (2) close to a box (3.1 ) on the product group feeding conveyor (5),• upper axis vacuum pads (2.6.3) located in the said upper axis group (2.6) hold the said box (3.1 ) by vacuuming it from its front surface.

3. A method according to claim 2, wherein; the upper axis group (2.6) that grips the box (3.1 ) on its front surface moves in the A direction and takes the box (3.1 ) into the gripper unit (2).

4. A method according to claim 3, wherein; the lower axis vacuum pads (2.5.5) in a lower axis group (2.5) located in the gripper unit (2) hold the lower surface of the box (3.1 ) by vacuuming.

5. A method according to claim 4, wherein; the gripper unit (2) is rotated 180° together with the robot arm (1.1 ) and the box (3.1 ) is turned upside down, making the products (3.2) inside ready to be unloaded.

6. A method according to claim 5, wherein;• the robot arm (1.1 ) moves the gripper unit (2) onto the product exit conveyor (6),• the upper axis group (2.6) and the lower axis group (2.5) move synchronously in the B direction,• the robot arm (1.1 ) moves the gripper unit (2) in the C direction and the products (3.2) are placed on the product exit conveyor (6).

7. A method according to claim 6, wherein; the upper axis group (2.6) and the lower axis group (2.5) move synchronously in the A direction and the empty box (3.1 ) with the products (3.2) removed is taken into the gripper unit (2).

8. A method according to claim 7, wherein;• the robot arm (1.1 ) moves the gripper unit (2) onto the box folding station (4),• the lower axis group (2.5) remains in the reverse position in the A direction,• the lower axis vacuum pads (2.5.5) stop vacuuming the box (3.1 ),• the upper axis group (2.6) moves to the forward position in the B direction,• the upper axis vacuum pads (2.6.3) stop vacuuming the box (3.1 ) and the empty box (3.1 ) is left in the box folding station (4).

9. A method according to claim 8, wherein; the said box folding station (4) folds and stacks the empty box (3.1 ).

10. A system in which the boxes (3.1 ) containing bottle type products (3.2) are taken from at least one product group feeding conveyor (5) and the products (3.2) inside are automatically discharged onto at least one product exit conveyor (6), characterized in that; it comprises: a robot (1 ) and at least one robot arm (1.1 ) capable of moving in multiple axes,• at least one gripper unit (2) that can be attached to the end of the said robot arm (1.1 ),• at least one lower axis group (2.5) that can move linearly in the A and B directions within the said gripper unit (2),• at least one upper axis group (2.6) that can move linearly in the A and B directions within the said gripper unit (2),• a lower axis vacuum pads (2.5.5) that grip the box (3.1 ) by vacuuming it from its lower surface in the said lower axis group (2.5),• upper axis vacuum pads (2.6.3) that grip the box (3.1 ) by vacuuming it from its front surface in the mentioned upper axis group (2.6)11. A system according to claim 10, wherein; it comprises a body block (2.1 ) that houses the equipment in the gripper unit (2) and has a volume in its structure that can accommodate the boxes (3.1 ).

12. A system according to claim 11 , wherein; it comprises a height adjustment mechanism (2.2) that allows the gripper unit (2) to move on the vertical axis to adapt to boxes (3.1 ) and product groups (3) of different heights.13.A system according to claim 12, wherein; the said length adjustment mechanism (2.2) comprises gripping jaws (2.3), which are gripping movable parts.

14. A system according to claim 12, wherein; it comprises a jaw indexing pin (2.3.1 ) that performs the height adjustment of the said length adjustment mechanism (2.2).15.A system according to claim 13, wherein; it comprises jaw locking pins (2.3.2) that lock the adjusted gripping jaws (2.3).

16. A method according to claim 10, wherein; it comprises:• lower axis linear piston bearings (2.5.2) that enable the lower axis group (2.5) to be movable linearly in the A and B directions within the gripper unit (2),• a lower axis drive motor (2.5.4) and a lower axis drive shaft (2.5.1 ) that provide the necessary drive for movement.

17. A system according to claim 10, wherein; the lower axis group (2.5) comprises a lower axis base plate (2.5.3) which serves as a carrier for the lower axis vacuum pads (2.5.5).

18. A system according to claim 10, wherein; it comprises at least one vacuum pad cylinder (2.5.6) that moves in the C and D directions, bringing the vacuum pads (2.5.5) into contact with or separating the lower surface of the box (3.1 ).19.A system according to claim 10, wherein; it comprises: • upper axis linear piston bearings (2.6.2) that enable the upper axis group(2.6) to be movable linearly in the A and B directions within the gripper unit (2),• upper axis drive motor (2.6.4) and upper axis drive shaft (2.6.1 ) which provide the necessary drive for movement.

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