Patent Application
20100031612
The present invention concerns an apparatus for and a method of packaging stackable objects, in particular printed products, in a container which has at least a first container portion with a bottom and with side walls extending from the bottom, wherein the container portion is open at the side opposite to the bottom. In particular the invention concerns an apparatus for and a method of packaging printed products in telescopically fitted lid boxes.
Printed products such as for example brochures, books or also loose sheets (for example forms, business papers or the like) are frequently packaged in so-called telescopically fitted lid boxes or telescope-type boxes. Telescope-type boxes have a bottom portion and a lid portion which is of a substantially similar structure in relation thereto and which is of slightly greater length and width, wherein in the packaging operation the bottom and lid portions are telescopically fitted over the stack of products formed from the printed products, from opposite sides of the stack, with the lid portion engaging over the bottom portion.
Telescope-type boxes are classified as ‘type 03’ in accordance with the standard of the FEFCO (European Associations of Corrugated Board Manufacturers), which is usual in the packaging area.
To ensure stackability of filled telescope-type boxes it is known that, in the packaging operation for the stackable products, firstly the bottom portion is generally filled with a certain upward oversize (that is to say extending beyond its actual height) by hand with the stack of products so that when a plurality of containers are stacked one above the other, the weight of the respectively superposed container is carried by the products disposed therebeneath and does not have to be absorbed by the side walls of the containers. Then the lid portion is telescopically fitted over the stack provided with the bottom portion, from the top side of the stack, with the dimensions of the lid portion being so selected that it fits over the bottom portion. As a result the consequence of this can be that the height of the filled telescopic-type box varies in dependence on the height of the stack of products accommodated therein.
The above-described packaging operation is usually performed manually by one or more people disposed at the end of a paper processing line, and that, with the high delivery that it is sought to achieve in respect of the paper processing line (present day installations can typically produce up to some hundred products per minute, depending on the number of pages in the individual printed product), is linked to a large amount of work and—with an increase in the number of packaging staff—leads to space problems because of the generally constricted conditions. In addition manual introduction of the products signifies a high level of physical stress on the corresponding people as the corresponding stacks of products which often weigh up to several kilograms have to be lifted and fitted into the boxes.
DE 37 08 896 A1 discloses an apparatus for filling and closing a container, preferably in the form of a box, with products in stack form, in which the products to be introduced into the box are introduced from below into the container to be filled which is initially still open and the underside of which is then closed and then a suitable lid is fitted thereon. That procedure however is not suitable for telescope-type boxes which usually have a fixed bottom. In addition subsequent closure of the bottom when the items are introduced thereinto generally leads to the disadvantage of a reduced load-carrying capacity on the part of the bottom, in comparison with a bottom which is closed from the outset.
Having regard to the above-outlined background, the object of the present invention is to provide an apparatus for and a method of packaging stackable products, in particular printed products, by means of which the stacked products can be packaged in an automated procedure in a container having a container portion, in which there are from the outset a closed bottom and side portions, as is the case in particular with a telescope-type box portion.
The aforementioned object is attained by an apparatus in accordance with the features of independent claim 1 and a method in accordance with the features of independent claim 28.
Advantageous configurations are set forth in the appendant claims.
An apparatus according to the invention comprises:
The term ‘product stack’ is used in accordance with the invention for the stack which is still unpackaged; the term ‘stack’ is intended to denote the product stack already provided with the first container portion.
In that respect the terms ‘product stack’ and ‘stack’ respectively, in connection with the present invention, are intended not just to embrace the situation where corresponding individual products are stacked one above the other, that is to say vertically. Rather, it is also possible to deal with stacks in which a plurality of products are arranged lying in mutually juxtaposed relationship and with the side surfaces against each other. It is also possible to package a plurality of mutually juxtaposed vertical individual stacks, for example two mutually juxtaposed stacks of printed products of DIN-A5 format which overall afford a surface of the size of a DIN-A4 sheet.
The stack preferably has a rectangular base surface and involves the shape of a parallelepiped. In accordance with the invention however it is also possible to process product stacks of a differing base surface, for example cylindrical stacks.
In accordance with the present invention it is possible to process such diverse configurations as in the packaging operation the stacks are handled in such a way that displacement of the individual products of a stack relative to each other is prevented.
It will be appreciated that the invention can also be used for packaging individual products which are not in stack form, into a respective container (for example for particularly ‘thick’ individual products such as for example printed products, in respect of which only a single product fits into a container).
The containers used in the context of the invention preferably involve boxes, particularly preferably telescope-type boxes. Alternatively however it is also possible to use containers consisting of materials which are entirely or partially produced from substances such as plastic materials or fibers including textile and glass fibers.
Preferably the first fitting-over device is adapted to fit the first container portion over the product stack from above. That provides that a product stack resting on a support surface can remain thereon and thus slipping of the products is avoided. In accordance with an alternative embodiment of the invention however it is also conceivable that the first container portion is fitted from the side, with its open side, over the stack, in which case the product stack would have to be lifted somewhat. The fitting-over operation signifies a relative movement of the container portion with respect to the product stack; in that case both the box portion and/or the product stack can be moved. Preferably the product stack remains immobile during the fitting-over operation while the box portion is moved thereover. The turning device is preferably adapted for turning the stack provided with the first container portion, about a horizontal axis, through an angle of about 180°. With such a rotation through 180°, the arrangement passes through conditions in respect of which it is necessary to ensure that the products do not fall out during the turning operation, for which reason the turning device has suitable retaining means which preferably delimit the open side of the first container portion or bear against products possibly projecting beyond the edge of the first container portion.
Preferably the covering device is in the form of a second fitting-over device which subsequently to the turning operation fits a second container portion which has a lid and side walls extending from the lid and which is open at the side opposite to the lid over the stack. That second container portion is thus preferably of a similar configuration to the first container portion, but of a slightly larger base surface, so that the side portions can slide over the stack and over the first container portion. Preferably the second container portion is the lid portion of a telescope-type box.
In alternative configurations of the invention it is also conceivable that closure of the container is effected by parts of the side portions of the first container portion, which side portions project beyond the product stack, are folded over to afford a lid. In this case the first container portion cannot be filled with products, to the edge. Closure can also be effected for example by means of elements in belt form which embrace the stack, or other means known in the state of the art.
In a preferred embodiment of the invention there is provided a transport device having a transport path, along which one or more product stacks or stacks provided with the first container portion is or are respectively firstly fed to the first fitting-over device, then the turning device and then the covering device. In that way the fitting-over operation, the turning operation and the covering or closing operation can take place simultaneously. Alternatively it is also conceivable for two or three of those steps to take place at the same location, in which case in addition a feed or discharge of the unpackaged or packaged product stacks respectively is also to be ensured. Preferably the transport path is formed by at least one roller track; it can however also involve a conveyor belt, a chute or the like.
In a preferred embodiment of the invention an apparatus for packaging stackable products, in particular printed products, in telescope-type boxes, wherein each telescope-type box has a bottom portion and a lid portion, has the following devices:
The arrangement according to the invention of two fitting-over devices with a turning device disposed therebetween, along the transport section of a transport device, makes it possible for the operation of fitting a bottom portion and a lid portion respectively, that is required for packaging the stacked products in telescope-type boxes, from mutually opposite sides of the product stack, to be performed in fully automated mode, that is to say without the need for manual intervention on the part of an operator. At the same time the serial ‘successive connection’ of the first fitting-over device, the turning device and the second fitting-over device means that the individual method steps necessary for implementing the telescope-type box packaging can be carried out simultaneously in a cyclically controlled mode with a corresponding increase in throughput. That means that, during the execution of the operation of turning a product stack already provided with the bottom portion fitted thereover, the next product stack can already be provided with a bottom portion in the first fitting-over device, and so forth. Accordingly in that way the apparatus according to the invention makes it possible to achieve a throughput of typically up to 20 packaged product stacks per minute.
Preferably the transport device is so adapted that it causes cyclic transport of the product stack or the stack.
Preferably the turning device has an axis of rotation above the transport path. Particularly preferably the turning device is adapted to pivot the product stack or stack substantially about its center of gravity.
In accordance with a preferred embodiment the apparatus has a control device, by means of which the first fitting-over device, the second fitting-over device and the turning device are actuable for implementing cyclic operation.
In accordance with a preferred embodiment the apparatus has a first magazine for receiving a stock of telescope-type box bottom portions and a second magazine for receiving a stock of telescope-type box lid portions, wherein the first and second magazines are adapted to receive the bottom and lid portions respectively in the flat condition thereof. In that way a large amount of bottom and lid portions which is desirable for the high throughput rates that the invention seeks to achieve can be stocked and incorporated into the automated packaging operation according to the invention, wherein the magazines are preferably arranged above the fitting-over devices whereby the required standing surface area for the apparatus according to the invention can be reduced, which is advantageous in particular for integration into existing paper processing lines with a small amount of available space.
In accordance with a preferred embodiment the first fitting-over device and/or the second fitting-over device has means for erecting the side walls of the bottom portion and the lid portion respectively. That configuration has the advantage that the bottom and lid portions which are preferably in the form of ‘erection boxes’ can be fed from the respective magazine to the fitting-over device in the same working step and at the same time erected, whereby it is possible to achieve a further increase in the working speed and thus the throughput of the apparatus according to the invention.
The first fitting-over device and/or the second fitting-over device can preferably have at least one pivotal arm with a suction device engaging a side wall of the container or lid portion. The box portions can thus be erected by applying suction to the side walls and performing a pivotal movement.
In addition the first fitting-over device can have means for lowering the erected bottom portion over the product stack and/or the second fitting-over device can have means for lowering the erected lid portion over the stack.
In that respect preferably the means for lowering the bottom portion and lid portion respectively are in the form of abutment elements which are guided from beneath the transport path along at least two mutually opposite sides of the product stack or stack respectively and at the upper ends of which there are respectively provided gripping elements which engage behind at least two oppositely disposed side walls of the container portions to be fitted over, whereupon the abutment elements are moved downwardly and in that case pull the respective container portion over the product stack or stack respectively. This configuration of the means for lowering the box portions in the form of abutment elements has the advantage that at the same time they ensure that the respective box portion can be pulled without tilting over the product stack or over the stack provided with the first box portion. It is conceivable that the above-described fitting-over devices can also be used in other packaging installations independently of other devices of the present invention, in particular the turning device.
In accordance with a preferred embodiment the apparatus has separating devices to permit selective removal of an individual container portion from the container portion stack of the magazines. That makes it possible to individually separate the bottom or lid portions prior to the removal thereof from the respective magazine and thus permits quick reliable access, even at high throughput rates.
Preferably the separating device has at least one brush bar which is so adapted that during removal of the respective lowermost container portion of the container portion stack it is brought laterally into engagement therewith and thereby blocks follow-on slipping movement of the container portion disposed above the container portion just being removed, and then the at least one brush bar is brought out of engagement with the container portion stack to cause follow-on slipping movement of the next container portion. Such a separating device can also be used independently of other devices of the present invention for individually separating mutually superposed flat objects.
In a preferred configuration the transport device has a transport path extending along the transport section and at least one guide element for guiding the product stack or the stack respectively on the transport path. That guidance of the product stack or the stack has the advantage that the products forming the stack do not in that case slip relative to each other, as could happen for example upon acceleration or deceleration of a product stack which is resting with its base surface on a conveyor belt.
In a preferred embodiment the transport path has at least three parallel rows of free-running roller tracks and each guide element has at least two guide entrainment members which are coupled together and which are movable between the roller tracks in a vertical direction into and out of the transport path plane and in a horizontal direction parallel to the roller tracks.
Particularly preferably there are provided at least three guide element pairs (preferably each in turn respectively comprising two guide entrainment members) for cyclic movement of the product stacks or the stacks along the transport path, wherein a first guide element pair is provided for moving a product stack from a feed position for the stacks as a starting position to the first fitting-over device as a target position, a second guide element pair for moving a stack from the first fitting-over device as a starting position to the turning device as a target position, a third guide element pair for moving a stack from the turning device as a starting position to the second fitting-over device as a target position, wherein each guide element pair at its starting position is moved out of the plane of the transport path in such a way that the two guide elements of a guide element pair are disposed in the transport direction immediately in front of and behind the product stack or the stack to be transported, then the guide element pairs are moved together with the product stack or the stack in the transport direction to the respective target position and then the guide element pairs are lowered again below the transport path and moved back to their starting position.
In addition there is also provided at least one further guide element for moving the stack from the second fitting-over device to a starting position.
Preferably the drive of the guide elements is so adapted that the two guide elements at least of the first guide element pair in the starting position are at a greater relative spacing in the transport direction than in the target position so that the product stack or the stack is thereby oriented in the transport direction. The spacing of the guide elements in the starting position is selected to be greater than the length of the respective stack to be guided so that the guide elements can move out of the transport path without encountering product stacks which are possibly not exactly oriented or which have slipped somewhat. The fact that the relative spacing of the guide elements towards the target position is reduced means that the stack on the one hand is oriented and on the other hand it is positioned precisely at the location of the next processing operation.
Preferably the first and third guide element pairs are formed at the same time as means for lowering the erected bottom or lid portion out of the magazines of the first and second turning-over device. In that way the lowering movement of the guide element pairs, that is required for the cyclic transport procedure, can also at the same time be used for fitting over the box portions, in which case the guide elements ensure that the box portions are fitted one over the other in trouble-free manner.
The above-mentioned guide elements permit orientation of the product stacks in respect of the side surfaces of the stacks, that are disposed transversely to the transport direction. In order also to orient the side surfaces of the stacks, that are oriented parallel to the transport direction, prior to the operation of fitting the box portions one over the other, and to guarantee blocking-free fitment of the box portions one over the other, pairs of side abutments arranged laterally on the transport path can be provided at the first and/or the second fitting-over device, which side abutments are applied prior to the fitting-over operation against the sides of the product stacks or the stacks, that are parallel to the transport direction, so that the product stacks or the stacks are properly oriented.
Preferably at the same time the side abutments can be in the form of means for lowering the erected bottom portion or lid portion out of the magazines of the first and second fitting-over devices.
Preferably the turning device can have a carrier which is arranged laterally of the transport path and which is rotatable about a horizontal axis extending transversely to the transport direction and on which a first and a second turning fork are linearly movably arranged, wherein a turning fork during the transport operation for the stack into the turning device is positioned in the plane or beneath the plane of the transport path, then for the turning operation the two turning forks are moved towards each other, wherein the stack is lifted off the transport path and is clamped between the two turning forks, then the carrier with the turning forks is rotated through about 180° and finally the turned stack is lowered on to the transport path again. Products are prevented from falling out by virtue of the stack being clamped between the turning forks. The above-described turning device can also be used independently of other devices of the present invention, in particular independently of the fitting-over devices.
Preferably there is further provided a device for automatic labelling of and/or inscription on the respective bottom portion and/or lid portion.
The invention further concerns a method of packaging stackable products in accordance with the features of independent claim 28.
In that respect the method according to the invention can also be implemented in an alternative embodiment (not described in greater detail with reference to the accompanying drawings) without an interposed turning operation. For that purpose for example it would be conceivable for the first box portion to be firstly fitted in telescopic relationship over the product stack. Then the stack together with the first box portion fitted thereover is lowered by means of grippers which come from above and which engage under the stack, into the upwardly open second box portion. Then an entrainment member disposed at the underside of the grippers can be folded over so that the grippers which are between the two box portions can be pulled out upwardly.
In regard to advantageous configurations of the method reference is made to the foregoing description in relation to the apparatus according to the invention.
Further configurations of the invention are to be found in the description and the claims.
The invention is described in greater detail hereinafter by means of a preferred embodiment by way of example and with reference to the accompanying drawings in which:
a-e show diagrammatic views of an apparatus according to the invention in different operating phases of the packaging procedure in time sequence,
Referring to
The magazines 4, 8 are arranged above the respective fitting-over devices 34, 35 and in that way make use of the ‘air space’ above the apparatus 10. To facilitate refilling the magazines 4, 8 in ongoing operation, the magazines can also be in the form of parallel dual magazines (not shown), in which case a feed is afforded from the respective one magazine shaft while the other can be refilled, whereupon the refilled magazine shaft can then be moved into the position of the feed shaft, for which purpose only a very short interruption in operation is required. Alternatively as will be appreciated the magazines can also be refilled ‘from above’ in ongoing operation.
In the fitting-over devices 34, 35 the box portions 23, 24 are respectively oriented and fitted over a stack. Disposed between the fitting-over devices 34 and 35 is the turning device 7 which pivots the stack provided with the bottom portion, about a horizontal axis extending transversely with respect to the transport direction denoted by P1, through an angle of 180° (see arrow P2).
As can be seen from
The time sequence of a packaging cycle is described in greater detail hereinafter by reference to the diagrammatic views in
In the situation shown in
b shows a situation which in time follows the situation in
A vertical lowering movement of all guide elements 30a, b-33 then follows, whereby the box portions 23 and 24 respectively, by virtue of the prestressing of the grippers 42, are pulled over the respective stacks 3a, 3c, in which case the suction grippers 6 remain opened in order not to impede the movement. That lowering movement is about 50% concluded in the
As can be seen from
In the region of the turning device 7 it can be seen from
d shows the turntable 13 during its rotary movement. During that rotary movement the guide elements 30a, b-33 which in that portion of the cycle are lowered completely beneath the transport path 1 are moved back in opposite relationship to the transport direction into their respective starting position. In addition a fresh product stack 3a′ is prepared. In order to orient the respective next box portion 23 or 24 in the magazines 4 and 8 respectively the suction grippers 6 are firstly closed. Now, brush bars 44 which prevent the box portion stacks in the magazines 4 and 8 respectively from a follow-on slipping movement upon removal of the lowermost box portion 23 or 24, by virtue of engaging laterally into the stack, are briefly moved out of their condition of lateral engagement so that the box portion stacks can perform a follow-on slipping movement and the following lowermost box portion 23 and 24 respectively comes to lie against the respective suction gripper 6. In that way the box portions can be reliably individually separated and isolated. Alternatively separation of the box portions can also be effected with probe fingers or the like, instead of the above-described brush bars 44.
In the situation shown in
So that, in the upward movement of the guide element pairs 30a, 30b, 31a, 31b and 32a, 32b, stacks which are slightly mispositioned and/or imprecisely oriented (‘skewed’) are not lifted off the transport path 1 and trouble-free operation of the apparatus 10 is guaranteed, the specified guide element pairs 30a, b-33 are firstly moved upwardly with a certain ‘safety distance’ of for example 1 cm on both sides from the expected stack position above the plane of the transport path 1 (safety distance not shown). During the transport procedure the front guide elements 30a, 31a, 32a and the rear guide elements 30b, 31b, 32b are moved towards each other by a mechanism which causes a relative movement between those groups of guide elements, more specifically until the spacing is reduced approximately to the dimensions of the stacks in the transport direction. In that way the stacks 3a-3c are exactly positioned in the transport direction and stacks which have possibly slightly slipped out of place are aligned.
As can be seen from the detail views of the fitting-over devices shown in
The grippers 43 are further designed in such a way that they press the box portion edge against the upper edge of the side abutments 11a, 11b and 12a, 12b respectively and in that way clamp the box portion respectively fast between the grippers 43 and the side abutments 11a, 11b and 12a, 12b, thereby additionally ensuring that the box portion during the lowering movement follows that movement. In that respect the clamping force is so selected that in its end position in which it bears against the product stack, the box portion automatically slips out of the clamping arrangement without being damaged in that situation.
During the transport movement of the stacks 3a and 3c respectively the spacing of the side abutments 11a and 11b, 12a and 12b is increased somewhat by an actuator. Prior to the operation of fitting the box portions one over the other the side abutments 11a, 11b and 12a, 12b respectively move together whereby the stacks 3a and 3c respectively disposed therebetween are aligned and centered in the transverse direction.
The position and maximum extension height of the guide elements 30a, b-33 and of the side abutments 11a, 11b, 12a, 12b can be adapted to the dimensions of the respective product stack 3a. In that respect the extension height is preferably so selected that the uppermost printed product of the product stack 3a is also still protected from unwanted displacement.
Alternatively it is possible to use any other suitable system for erecting the container portions. For example, in accordance with an alternative embodiment (not shown), in a modification of the
Many different deviations from the above-described embodiment are conceivable in accordance with the invention. Thus, instead of a further telescope-type box being fitted over the bottom portion, closure of the box can also be effected by folding over closure elements provided on the first container portion, into a closure position. In addition the invention can also be used not only in connection with telescope-like boxes but also in connection with all packaging tasks in which material in stack form is to be packaged in an upwardly open container. It is also conceivable, instead of transportation of the stacks between a first fitting-over device, a turning device and a second fitting-over device, for those operations to be respectively implemented at the same location.
| Number | Date | Country | Kind |
|---|---|---|---|
| 07103085.2 | Feb 2007 | EP | regional |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/EP08/51954 | 2/18/2008 | WO | 00 | 8/20/2009 |
