The present invention relates to an automated apparatus for handling bags. In particular, but not exclusively the invention relates to an apparatus for opening and placing plastic vest-type bags as part of an industrial-scale, automated goods handling operation, such as a grocery packing operation. The invention also relates to an associated automated method of handling such bags and to a packing process involving automated bag handling.
Picking-and-packing processes, in which ordered goods are retrieved from a storage location in a storage facility or warehouse and packed into a container for delivery to a customer, are commonplace in many industries. In particular, the online grocery retail sector is rapidly growing and is becoming increasingly reliant on automation of parts of the process to increase efficiency and to achieve the desired throughput of orders.
A typical online grocery order will include a large number of different products, each with differing shape, size, weight, fragility and perishability. These products must be packed carefully into suitable packaging for delivery to customers. It is convenient to use vest-type carrier bags made from plastics film material for this purpose, because such bags are low-cost and space efficient and are suitable for holding almost all of the different products in a typical grocery order. Furthermore, bags of this type have integral handles which not only facilitate convenient carrying of the filled bags as part of a delivery to a customer, for example, but also enable the bags to be securely placed and held within a container, for picking and packing of products in an order picking system.
During the preparation of the order, it is often necessary or advantageous to ensure that the bags are held open in a predetermined location on a production line arrangement to facilitate the placing or dropping of items into these bags. For example, this location can be inside a container, such as a rigid-walled box or crate, known in the art as a tote, that can be transported between sites within a warehouse on conveyor belts or by other means within a warehouse, and loaded onto a van for delivery to customers. Alternatively, bags can be held open on static racks in picking locations where product may be added, or on a conveyor arrangement that moves the bags through one or multiple picking locations.
While the opening, filling and sealing of plastic bags as part of a packaging process for bulk goods is a well-established technology, the handling of plastic vest-type plastic carrier bags with handles in an automated system is not well-known. In particular, significant challenges are presented when attempting to apply known technology to the automatic handling of bags of this type in a high-throughput industrial-scale process of the type desired to increase the efficiency of online grocery retail operations. One particular challenge is the weak structural integrity of plastics vest-type carrier bags which makes reliable automated manipulation technically difficult.
Against this background, it would be desirable to provide apparatus capable of handling, opening and placing bags, in particular vest-type carrier bags, in an automated system suitable for high-throughput industrial-scale use.
The present innovations describe some of the components for an automatic device for the opening and placing of vest-type bags in a way which keeps them securely open in a predetermined position for subsequent filling.
According to a first aspect of the present invention, there is provided an apparatus for automatically handling vest-type bags in the context of an automated packing process, the bags having at least one handle in the form of a loop comprising two strips joined at one end of the handle, and the apparatus comprising at least two fingers extending parallel to one another, the fingers being arranged to move apart to increase the spacing between the fingers along a bag-opening direction; wherein the apparatus is arranged to insert the fingers between the strips of the handle, and to move the fingers apart in the bag-opening direction to part the strips of the handle in the bag-opening direction.
In preferred examples of the invention, the apparatus is used in the context of an automated process for packing items such as groceries, but the invention is not limited in this respect.
In preferred embodiments of the invention, the apparatus is configured to manipulate vest-type bags comprising two sheets of film-like material and having a non-rigid form. Such bags are commonly found in supermarkets for packing and transporting groceries etc.
Advantageously, the apparatus may be configured to impart a temporary rigidity to the opened bag to enable its automated manipulation. The temporary rigidity imparted to the bag enables it to be manipulated as though it was a more conventional rigid packaging. It allows for the bag to be placed within a container, such as a tote, which acts as a frame for the non-rigid bag and enables the rigidity to be retained until such time as the bag has been filled with goods, which then themselves provide a structure about which the bag will be supported and will not collapse.
Expressed in other terms, therefore, the present invention provides an apparatus for manipulating bags comprised of two sheets of film-like material and having a non-rigid form, the apparatus comprising at least two fingers extending parallel to one another and movement means for moving the fingers, wherein the movement means is arranged to insert the fingers between the two sheets and to move the fingers into a position and orientation which imparts a temporary rigidity to the bag to enable its automated manipulation.
The apparatus may advantageously comprise suction means for engaging each strip of the handle. The suction means may be configured to grip each strip of the handle so as to part the strips before the fingers are inserted.
The apparatus is preferably configured to insert the fingers when the bag is in a closed configuration where the two sheets are substantially adjacent each other and the bag is unable to receive items, and to separate the fingers to place the bag in an open configuration where the two sheets are substantially separated and the bag is open to receive items.
Movement of the fingers in the bag opening direction provides a first plane of rigidity. The apparatus may be further configured to change the orientation of the fingers to provide a second plane of rigidity different to that of the first plane of rigidity. This greatly enhances the temporary rigidity of the bag to make subsequent automated manipulation of the bag by the apparatus more reliable.
Accordingly, in preferred embodiments of the invention, the fingers are moveable between a first position in which the fingers are inserted into the handle, and a second position in which the fingers pull the loop of the handle outwards from the bag. The first position is preferably substantially perpendicular to the second position. Both the first position and the second position are preferably substantially perpendicular to the bag opening direction, or are in a plane that is substantially perpendicular to the bag opening direction. In preferred embodiments of the invention, the first position is a generally horizontal position, and the second position is a generally vertical position. The fingers are preferably pivotable between the first and second positions about an axis that extends substantially parallel to the bag opening direction.
The apparatus may comprise a carriage having a pivotable part to which the fingers are mounted. The carriage may further comprise a roller connected to the pivotable part and co-operable with a cam track of a guide component of the apparatus, the cam track being arranged such that movement of the carriage along the guide component causes pivoting of the fingers from the first position to the second position.
The apparatus may further be configured to lower the bag towards a container by downward motion of the fingers. Advantageously, movement of the fingers from the first position to the second position may be driven by this downward motion.
Where the orientation of the fingers has been changed, e.g. when the fingers are moved from the first position to the second position, small regions of non-rigidity can subsequently arise in the structure of the bag. Preferably, the apparatus is arranged to provide further means for engaging the bag to provide a temporary rigid structure at the small regions of non-rigidity. The engaging means may conveniently take the form of a push plate which can be moved to be adjacent the regions of non-rigidity. This is particularly important in the region of the bag handles and the opening of the bag, where control of the rigidity of the bag is most important in its subsequent handling.
The push plate or other engaging means may be arranged to tension the handle and constrain side portions of the handle in the bag-opening direction. For example, a push plate may be inserted into the loop of a respective handle and moved away from the fingers in a direction substantially perpendicular to the bag-opening direction so as to tension the handle and constrain the side portions in the bag-opening direction. The push plate may be configured to be inserted into the loop of a respective handle and moved away from the fingers when the fingers are in the second position.
Stretching the handle in this way facilitates the subsequent placement of the bag into a container. For example, once the bag has been opened, it may then be placed into a container configured to support the bag in the open configuration. The container may have suitable recesses, such as slots, which may be provided in a rim of the container. The side portions of the bag handles may be inserted into these slots and the slots may be suitably spaced apart on the rim of the container so that the bag is supported inside the container in the open configuration. Stretching the handle by means of the push plates, or otherwise, causes the side portions of the handle to straighten and facilitates their insertion into the recesses of the container.
The bag when in an open configuration may occupy and have a footprint area associated with it. The apparatus is preferably arranged to move the fingers into a position outside of the footprint area to enable placement of the bag into the container and subsequent disengagement of the apparatus from the bag. By having the fingers outside the footprint, the disengagement is made easier. Also, the rigidity provided by the apparatus may be maintained by transfer of the bag to the support provided by the rigid walls of the container.
The apparatus may further comprise a frame having first and second upstanding legs spaced apart to define a bag-receiving zone in between. A first pair of fingers is preferably mounted to the first leg, and a second pair of fingers is preferably mounted to the second leg. The legs may be configured to pivot about respective axes that extend substantially parallel to the bag-opening direction so as to move the legs inwardly and outwardly with respect to the bag. The inward movement of the legs preferably causes the respective pairs of fingers each to be inserted between the strips of a respective handle of the bag.
Within the same inventive concept there is also provided a packing line for packing items into vest-type bags, the packing line comprising the automated bag-handling apparatus described above. Further, the present invention extends to a packing facility, for example a warehouse or other such order picking and packing facility, comprising such a packing line. For example, the bag-handling apparatus may be employed to open bags automatically and optionally to place the opened bags into totes or other such containers that support and retain the bags in the open configuration. The totes may then be moved along the packing line to packing stations where items, such as groceries for example, may be placed inside the bags in order to fulfil customer orders.
According to a second aspect of the present invention, there is provided an automated method of handling vest-type bags in the context of an automated packing process, the bags having at least one handle in the form of a loop comprising two strips joined at one end of the handle, and the method comprising: inserting at least two fingers of an automated bag-handling apparatus between the strips of the handle, and moving the fingers apart in the bag-opening direction to part the strips of the handle in the bag-opening direction.
The method may advantageously comprise parting the strips of the handle by means of suction before the fingers are inserted between the strips.
The method preferably involves imparting temporary rigidity to the opened bag by means of the fingers to enable automated manipulation of the bag.
The method may comprise moving the fingers from a first position to a second position so as to pull the loop of the handle outwards from the bag. The first position may be substantially perpendicular to the second position. In preferred embodiments of the invention the first position is a generally horizontal position, and the second position is a generally vertical position.
The method may comprise turning the fingers about an axis that extends substantially parallel to the bag opening direction in order to move the fingers between the first and second positions
The method may comprise lowering the open bag into a container by moving the fingers in a downwards direction. The downward motion of the fingers may drive the movement of the fingers from the first to the second position via a cam mechanism.
The method may further comprise pulling the handle taut and constraining side portions of the handle in the bag-opening direction.
The method may comprise inserting a push plate into the loop of the handle and moving the push plate away from the fingers in a direction substantially perpendicular to the bag-opening direction. This serves to pull the handle taut and constrain the side portions of the handle in the bag-opening direction. The method may involve inserting the push plate into the loop of the respective handle when the fingers are in the second position.
The method may comprise placing the open bag in a container configured to support the bag in an open configuration. The method may further comprise inserting the constrained side portions of the at least one handle into respective recesses defined in the container. The method may comprise releasing the bag from the handling apparatus by moving the fingers together and moving the fingers further in a downwards direction.
The method may comprise supporting the bag in a bag-receiving zone defined between first and second pairs of fingers and moving the fingers inwardly with respect to the bag so as to insert the respective pairs of fingers between the strips of a respective handle of the bag.
The inventive concept includes a method of packing items such as groceries into vest-type bags, the method comprising automatically handling vest-type bags in accordance with the above method. The invention also provides a packing facility in which items such as groceries are packed into vest-type bags in accordance with the packing method.
According to a third aspect of the present invention, there is provided a method of packing items such as groceries into vest-type bags, the method comprising:
The method may comprise automatically placing a plurality of bags into the same container before step (d).
Preferably step (a) of the method comprises providing an automated bag handling apparatus as described above in relation to the first aspect of the present invention. However, other bag handling apparatuses may instead be used in the otherwise novel and inventive method.
Preferably the automated bag handling apparatus is configured to perform operations (i) and (ii) in accordance with the method of the second aspect of the present invention. However, other bag handling techniques may instead be used in the otherwise novel and inventive method.
It should be appreciated that optional features described above in relation to any particular aspect of the invention are equally applicable to the other aspects of the invention.
Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
In the present embodiment, vest-type bags 10 of the type shown in
The benefit of using a vest-type bag 10 is that not only can it subsequently be used for carrying the bag as part of the delivery to the customer, but also that it allows the bag 10 to be securely placed and held in a container and thus facilitate the picking and packing of product in an order picking system.
The present embodiment includes a device for inserting vest-type bags 10 of the type shown in
The process starts with one carrier bag 10 being dispensed from a roll into a location in which four suction cups 24 of a suction device are applied to the handles 14 to separate the layers of film in each handle 14, as shown as Step 1 in
The suction cups 24 pull the handles 14 slightly open in a direction perpendicular to the bag plane, known hereafter as the bag opening direction, and the body portion 12 of the bag 10 hangs generally vertically downwards from the handles 14.
Once the handles 14 are opened by the suction device, it is necessary to gain positive mechanical control of the handles 14, in order to open the bags 10 and position them to the intended location.
In the present embodiment, this is achieved by means of fingers 22, which are inserted into the opened handle 14 (namely between the two pulled-apart portions of the bag handles) and then moved apart to gain full and positive mechanical control of the bag 10. Referring additionally to
As shown in Step 2 in
When the bag 10 is moved into position, the legs 30 are held in a retracted position, so that the tops of the legs 30 are splayed outwardly (not shown). In Step 2 of the process, the legs 30 are moved inwards by actuators 36 into the position shown in
In Step 3, each pair of fingers 22 is separated to stretch the handles 14 open. The fingers 22 move apart in the bag opening direction, into the configuration shown in
Referring back to
The fingers 22 move into the upright configuration automatically as the carriage 34 moves downwards. Any suitable means can be used to achieve this action. In one embodiment of the invention, movement of the fingers 22 is controlled using a cam mechanism driven by the downwards motion of the carriage 34. An example of a suitable cam mechanism is shown in
As shown in
Further links 54, 56 connect the end of the driveshaft 50 opposite the roller 46 to the plate 48, so that turning movement of the driveshaft 50 causes the plate 48 to move from a horizontal orientation to a vertical orientation as the roller 46 moves downwards along the cam track 44. One pair of fingers 22, and the associated mechanism that moves the fingers 22 together and apart, are mounted on and generally parallel to the plate 48, so that the downward movement of the carriage 34 causes the fingers 22 to move into their upright configuration.
Once the fingers 22 have moved into the upright position in Step 4, the handles 14 are then manipulated to stretch them fully open ready to engage with the container 16. This is useful as the rotation of the fingers moves the handles into a position at which one side edge 57a of the handle 14 will be relatively taut and the other side edge 57b will be relatively slack. So, in Step 5 (see
In this position, the plastic film of the handle 14 is fully stretched into a generally rectangular shape and held in a precisely defined position, as shown in the top view of
Referring back to
In Step 7, when the bag 10 is positioned in the container 16, with the handles 14 engaged with the slits 20 in the container 16, the push plates 58 are lifted and withdrawn and the fingers 22 are moved together in the reverse of the bag opening direction, to disengage the fingers 22 from the handles 14. The fingers 22 are then lowered further to disengage fully the apparatus from the container 16. The bag 10 is now fully inserted into a defined and secure location in the container 16.
In Step 8 of the process (not illustrated), the container 16 is then moved on by means of a conveyor belt, and is replaced by another empty container 16. The legs 30 of the frame are moved outwards and the carriages 34 moved upwards to return the apparatus to its starting position, and the process described above is then repeated to place a bag 10 into the new container 16.
The apparatus may be configured to place multiple bags into each container 16. A first bag 10 is placed at a first location in the container, and the container 16 may then be indexed to another position, to insert a second bag 10 at a second location in the same container. The steps above are then repeated to place further bags in the container. In the present embodiment, four pairs of slits 20 are provided on the rim of the container 16 which permits three bags 10 to be held within the current container 16 as adjacent bags share the same slit in the container. However, the container and the process could readily be designed to hold greater or fewer numbers of bags as required. The automated nature of the bagging process of the present embodiment enables a bagging rate of ten bags per minute to be accurately handled by the apparatus.
Number | Date | Country | Kind |
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1220784.1 | Nov 2012 | GB | national |
Filing Document | Filing Date | Country | Kind |
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PCT/GB2013/053055 | 11/19/2013 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2014/076507 | 5/22/2014 | WO | A |
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Number | Date | Country | |
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20150291296 A1 | Oct 2015 | US |