GB2565312A - Tray erector - Google Patents

Tray erector Download PDF

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Publication number
GB2565312A
GB2565312A GB1712744.0A GB201712744A GB2565312A GB 2565312 A GB2565312 A GB 2565312A GB 201712744 A GB201712744 A GB 201712744A GB 2565312 A GB2565312 A GB 2565312A
Authority
GB
United Kingdom
Prior art keywords
tray
tool
forming tool
forming
guides
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB1712744.0A
Other versions
GB201712744D0 (en
GB2565312B (en
Inventor
Lovedale Antony
Quinn Alan
Coles-Abell Horatio
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Active8 Robots Ltd
Original Assignee
Active8 Robots Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Active8 Robots Ltd filed Critical Active8 Robots Ltd
Priority to GB1712744.0A priority Critical patent/GB2565312B/en
Publication of GB201712744D0 publication Critical patent/GB201712744D0/en
Publication of GB2565312A publication Critical patent/GB2565312A/en
Application granted granted Critical
Publication of GB2565312B publication Critical patent/GB2565312B/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
    • B31B50/26—Folding sheets, blanks or webs
    • B31B50/44—Folding sheets, blanks or webs by plungers moving through folding dies
    • B31B50/46—Folding sheets, blanks or webs by plungers moving through folding dies and interconnecting side walls
    • B31B50/48—Folding sheets, blanks or webs by plungers moving through folding dies and interconnecting side walls by folding or tucking in locking flaps
    • B31B50/50—Folding sheets, blanks or webs by plungers moving through folding dies and interconnecting side walls by folding or tucking in locking flaps by interengaging tongues and slots
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
    • B31B50/26—Folding sheets, blanks or webs
    • B31B50/44—Folding sheets, blanks or webs by plungers moving through folding dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
    • B31B50/02—Feeding or positioning sheets, blanks or webs
    • B31B50/04—Feeding sheets or blanks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
    • B31B50/02—Feeding or positioning sheets, blanks or webs
    • B31B50/04—Feeding sheets or blanks
    • B31B50/07—Feeding sheets or blanks by air pressure or suction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/20—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form
    • B65D5/22—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form held erect by extensions of one or more sides being doubled-over to enclose extensions of adjacent sides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B2100/00—Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs
    • B31B2100/002—Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs characterised by the shape of the blank from which they are formed
    • B31B2100/0024—Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs characterised by the shape of the blank from which they are formed having all side walls attached to the bottom
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B2110/00—Shape of rigid or semi-rigid containers
    • B31B2110/30—Shape of rigid or semi-rigid containers having a polygonal cross section
    • B31B2110/35—Shape of rigid or semi-rigid containers having a polygonal cross section rectangular, e.g. square

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Container Filling Or Packaging Operations (AREA)

Abstract

Tray erecting apparatus with movable inner forming tool 95 which is movable and maneuvers a flat, unfolded tray 10 over a fixed outer forming tool 40, where the inner forming tool can be plunged into the outer forming tool to erect the tray. The inner tool may be mounted to a robot arm manipulator and may include forming surfaces or guides contoured to fold flaps of a tray when the inner tool plunges. The tools may include actuators for folding and locking tabs. The actuators may be replaceable and be moved between the inner and outer tool. The apparatus may include a table which may comprise a jig and an infeed hopper for receiving flat trays. The apparatus may include an outfeed conveyor. A collaborative robot may be used to allow uncaged operation. Also claimed is a method for erecting a tray.

Description

TRAY ERECTOR
The present invention relates to a method and apparatus for erecting a self-locking tray automatically via a combination of shaped tools and robot manipulation.
According to an aspect of the present invention this is a tray erecting apparatus comprising a two-part tool including an outer forming tool and an inner forming tool, the outer forming tool is fixed, the inner forming tool is movable and, in use, can manoeuvre a flat, unfolded tray over the outer forming tool, and the inner forming tool can be plunged into the outer forming tool to erect the tray.
The inner tool may be mounted to a robot arm manipulator. The manipulator can, for example, allow the tool to be moved to collect a flat tray, position it over the outer forming tool and plunge the tray into the outer forming tool.
The inner forming tool may include one or more forming surfaces and/or guides contoured to fold the flaps of a tray when the inner forming tool plunges a tray thereinto.
The outer and/or inner tools may include actuators for folding and locking tabs on a tray.
The apparatus may further comprise a tray forming table.
The table may include a tray forming jig.
The table may include an infeed hopper for receiving a stack of flat trays.
The apparatus may further comprise a robot pedestal.
The apparatus may further comprise an outfeed conveyor.
In some embodiments the apparatus is implemented using one or more collaborative robots. This may enable an uncaged solution with a small footprint. A further aspect provides a method of erecting a tray from a flat, unfolded, position to an erected, folded position, the method comprising the steps of: providing a fixed outer tool and a movable inner tool; using the inner tool to manoeuvre a flat, unfolded tray over the inner tool; and plunging the inner tool, with a tray attached, into the outer forming tool whereby to erect the tray. A robot arm manipulator may be used to manoeuvre the inner tool.
In some embodiments trays are picked via vacuum and adhered to the underside of the inner tool.
The shape and contour of guides within the outer forming tool may be used to erect the tray, for example by folding flaps.
In some embodiments the guides bring together major, sub-major, and minor flaps in a correct order with them interleaving correctly without jamming.
In some embodiments, while the inner and outer tools are nested with the tray in place, holding the major and minor flaps, actuators on the inner and outer tool move to fold and lock the tabs.
Upon completion the robot may retract the inner tool and attached tray from the outer tool and can then place it for filling or further manipulation.
Some aspects and embodiments provide a tray erector unit for SRP (shelf ready packaging).
Some aspects and embodiments provide robot tray erecting tooling.
In some embodiments the present invention provides a method and apparatus for erecting tab-locking cardboard trays as used in shelf ready packaging, ‘pizza boxes’ and other forms of cardboard self-locking trays.
Different aspects and embodiments of the invention may be used separately or together.
Further particular and preferred aspects of the present invention are set out in the accompanying independent and dependent claims. Features of the dependent claims may be combined with the features of the independent claims as appropriate, and in combinations other than those explicitly set out in the claims.
The present invention will now be more particularly described, by way of example, with reference to the accompanying drawings. (Fig I to 7).
The example embodiments are described in sufficient detail to enable those of ordinary skill in the art to embody and implement the systems and processes herein described. It is important to understand that embodiments can be provided in many alternative forms and should not be construed as limited to the examples set forth herein.
Accordingly, while embodiments can be modified in various ways and take on various alternative forms, specific embodiments thereof are shown in the drawings and described in detail below as examples. There is no intent to limit to the particular forms disclosed. On the contrary, all modifications, equivalents, and alternatives falling within the scope of the appended claims should be included. Elements of the example embodiments are consistently denoted by the same reference numerals throughout the drawings and detailed description where appropriate.
Unless otherwise defined, all terms (including technical and scientific terms) used herein are to be interpreted as is customary in the art. It will be further understood that terms in common usage should also be interpreted as is customary in the relevant art and not in an idealised or overly formal sense unless expressly so defined herein.
In the following description, all orientational terms, such as upper, lower, radially and axially, are used in relation to the drawings and should not be interpreted as limiting on the invention.
Figure I shows a flat, unfolded tray generally indicated 10.
In Figure 2 the tray 10 is shown in an erected, folded position without locking. Figure 2b shows a fully locked tray (after actuators have operated).
Apparatus 20 for converting a tray of the type shown from the flat position of Figure I to the erected position of Figures 2 is shown in Figure 3.
The apparatus 20 comprises a main frame or table 25 which includes a tray infeed hopper 30 for receiving a stack of flat trays 10, and a tray forming jig which defines an inner forming tool 40. A robot pedestal 45 is provided, in this embodiment being separate from the table and having wheels 50 so it can be moved. An outfeed conveyor 55 is provided adjacent the table for receiving folded trays.
The jig is shown in more detail in Figure 4 and comprises a pair of major frame members 60a, 60b joined by a pair of linear cross members 65a, 65b. A pair of generally U-shape cross members 70a, 70b depend from and extend between the frame members 60. Two minor L-shape frame members 75a-d depend from each of the cross members 65a, 65b and at their other end connect to respective U-shape cross members 70a, 70b.
The jig includes a plurality of curved guides 80 for causing folding of a tray in use.
The U-shape cross members 70a, 70b carry a pair of linear actuators 85.
Figure 5 shows a robot end of arm tooling on which in mounted an inner forming tool 95. The tool includes a pair of actuator arms 91. The tool 95 includes a plurality of vacuum suction cups 96.
The method of erecting to tray utilises a two part tool consisting of the outer forming tool 40 and the inner forming tool 95. The outer forming tool is fixed, while the inner forming tool is mounted to the robot arm manipulator.
The inner tool 95 is manoeuvred onto a flat, unfolded tray 10; the tray is picked via vacuum and adhered to the underside of the inner tool and moved above the outer forming tool, as shown in Figure 6.
The inner tool 95 with flat tray attached is then plunged into the outer forming tool 40 where the shape and contour of the guides 80 within the outer forming tool bring together the major, sub-major, and minor flaps in the correct order with them interleaving correctly without jamming.
While the inner and outer tools are nested with the tray in place, holding the major and minor flaps, the actuators 85, 91 on the inner and outer tool move to fold and lock the tabs.
Figure 7 shows the progression of the minor flap folding actuators and the way the actuators interleave; in this embodiment the interleaving of the folding actuators is key to the implementation.
In this embodiment the progression of guides is configured such that flaps move at different times and by different angles as they hit different guides through the plunge, such that they do not jam. It is a progression based on plunge depth, with each guide placed at a different point along the plunge to perform its role.
Upon completion the robot retracts the inner tool and attached tray from the outer tool and can then place it for filling or further manipulation.
Although illustrative embodiments of the invention have been disclosed in detail herein, with reference to the accompanying drawings, it is understood that the invention is not limited to the precise embodiments shown and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope of the invention as defined by the appended claims and their equivalents.

Claims (22)

1. Tray erecting apparatus comprising a two-part tool including an outer forming tool and an inner forming tool, the outer forming tool is fixed, the inner forming tool is movable and, in use, can manoeuvre a flat, unfolded tray over the outer forming tool, and the inner forming tool can be plunged into the outer forming tool to erect the tray.
2. Apparatus as claimed in claim I, in which the inner tool is mounted to robot arm manipulator
3. Apparatus as claimed in claim I or claim 2, in which the inner forming tool includes one or more forming surfaces and/or guides contoured to fold the flaps of a tray when the inner forming tool plunges a tray thereinto.
4. Apparatus as claimed in any preceding claim, in which the outer and/or inner tools include actuators for folding and locking tabs on a tray.
5. Apparatus as claimed in claim 4, in which the actuators are replaceable.
6. Apparatus as claimed in claim 4 or claim 5, in which the actuators can be moved between inner and outer tool to enable customisation of different tray configurations.
7. Apparatus as claimed in any preceding claim, further comprising a tray forming table.
8. Apparatus as claimed in claim 7, in which the table comprises a tray forming jig.
9. Apparatus as claimed in claim 7 or claim 8, in which the table comprises an infeed hopper for receiving a stack of flat trays.
10. Apparatus as claimed in any preceding claim, further comprising a robot pedestal.
I I. Apparatus as claimed in any preceding claim, further comprising an outfeed conveyor.
12. Apparatus as claimed in any preceding claim, in which the apparatus can be implemented using collaborative robots so as to enable an uncaged solution with a small footprint.
13. A method of erecting a tray from a flat, unfolded, position to an erected, folded position, the method comprising the steps of: providing a fixed outer tool and a movable inner tool; using the inner tool to manoeuvre a flat, unfolded tray over the inner tool; and plunging the inner tool, with a tray attached, into the outer forming tool whereby to erect the tray.
14. A method as claimed in claim 13, in which a robot arm manipulator is used to manoeuvre the inner tool.
15. A method as claimed in claim 13 or claim 14, in which a tray is picked via vacuum and adhered to the underside of the inner tool.
16. A method as claimed in any of claims 13 to 15, in which the shape and contour of guides within the outer forming tool erect the tray.
17. A method as claimed in any of claims 13 to 16, in which the progression of guides is configured such that tray flaps move at different times and by different angles as they hit different guides through the plunge, such that they do not jam.
18. A method as claimed in claim 17, in which the guide progression is based on plunge depth, with each guide placed at a different point along the plunge to perform its role.
19. A method as claimed in claim 18, in which the guides bring together major, submajor, and minor tray flaps in a correct order with them interleaving correctly without jamming.
20. A method as claimed in any of claims 13 to 19, in which while the inner and outer tools are nested with the tray in place, holding the major and minor flaps, actuators on the inner and outer tool move to fold and lock the tabs.
21. A method as claimed in any of claims 13 to 20, in which upon completion the robot retracts the inner tool and attached tray from the outer tool and can then place it for filling or further manipulation.
22. A method as claimed in any of claims 13 to 21, in which the method implementation is collaborative in nature and can be certified for uncaged operation in accordance with ISO 10218-2.
GB1712744.0A 2017-08-09 2017-08-09 Tray erector Active GB2565312B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB1712744.0A GB2565312B (en) 2017-08-09 2017-08-09 Tray erector

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GB1712744.0A GB2565312B (en) 2017-08-09 2017-08-09 Tray erector

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GB201712744D0 GB201712744D0 (en) 2017-09-20
GB2565312A true GB2565312A (en) 2019-02-13
GB2565312B GB2565312B (en) 2023-03-22

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023117645A3 (en) * 2021-12-23 2023-09-28 Ribbeck GmbH & Co. KG Method and apparatus for supplying a film to a film-covering station for covering at least one cardboard tray with film

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5971906A (en) * 1996-11-29 1999-10-26 Tharpe, Jr.; Johnny M. Tray forming apparatus and method
US20070037682A1 (en) * 2005-08-10 2007-02-15 Scholtes William J Tray erector
US20100263333A1 (en) * 2008-09-12 2010-10-21 Langen H J Paul Method and apparatus for forming containers with corrugated material
EP2363280A1 (en) * 2010-03-05 2011-09-07 All Glass S.r.l. Apparatus and procedure for making edged trays
US20140113787A1 (en) * 2012-10-19 2014-04-24 Rock-Tenn Shared Services, Llc Container forming apparatus and method
JP2017013335A (en) * 2015-06-30 2017-01-19 株式会社フジキカイ Box production device

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5971906A (en) * 1996-11-29 1999-10-26 Tharpe, Jr.; Johnny M. Tray forming apparatus and method
US20070037682A1 (en) * 2005-08-10 2007-02-15 Scholtes William J Tray erector
US20100263333A1 (en) * 2008-09-12 2010-10-21 Langen H J Paul Method and apparatus for forming containers with corrugated material
EP2363280A1 (en) * 2010-03-05 2011-09-07 All Glass S.r.l. Apparatus and procedure for making edged trays
US20140113787A1 (en) * 2012-10-19 2014-04-24 Rock-Tenn Shared Services, Llc Container forming apparatus and method
JP2017013335A (en) * 2015-06-30 2017-01-19 株式会社フジキカイ Box production device

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023117645A3 (en) * 2021-12-23 2023-09-28 Ribbeck GmbH & Co. KG Method and apparatus for supplying a film to a film-covering station for covering at least one cardboard tray with film

Also Published As

Publication number Publication date
GB201712744D0 (en) 2017-09-20
GB2565312B (en) 2023-03-22

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