Patent Grant
12151840
The present application claims priority of patent application No. PI2021003212, filed on Jun. 10, 2021. The entire disclosure of the above application is incorporated herein by reference.
The present application relates to a method and a system for packaging flexible articles. More particularly, the present application relates to a method and a system for automated packaging of a stack of flexible articles into an erected box without bulging the flexible articles and damaging the erected box.
In a gloves production line, gloves which are the finished products are usually packaged into packaging boxes during a product packaging process. Conventionally, this process is done by a human workforce whereby the gloves are stacked manually and inserted into the packaging boxes by workers. This packaging approach requires a large labour intensity and will result in a low glove packaging efficiency as the gloves may be misaligned or disoriented when being loaded into the packaging boxes. As a result, the gloves are bulky and bulgy. Furthermore, the quantity of stacked gloves to be packaged into the packaging boxes can be varied. A large quantity of the stacked gloves is difficult to be inserted into the packaging boxes as the height of the stacked gloves is higher than that of the packaging boxes. The workers need to manually flatten the stacked gloves so that they can fit into the packaging boxes. This manual operation of flattening the stacked gloves is inefficient and not reliable which can result in unflatten stacked gloves. The unflatten stacked gloves can damage the packaging boxes during the product packaging process, thereby producing bulky and bulgy packaging boxes. Other than using the human workforce, many packaging machines have been developed to automatically load the gloves into the packaging boxes. Most of the packaging machines load the gloves into the packaging boxes by pushing the gloves into the boxes through one of its side openings. This pushing operation may cause the packaging boxes to suffer from damages such as tears due to large friction generated between the gloves and any contact surface during its travel into the packaging boxes. Furthermore, the gloves may also be misaligned or disoriented when being pushed into the packaging boxes and this may affect an operation of closing side flaps of the packaging boxes. Due to this, the packaging boxes may look bulky and bulgy.
One exemplary technology of the packaging machines can be referenced from China Patent Publication No. CN202728596U disclosing a device for loading finished gloves into packaging boxes, which comprises a glove transition box installed in a transition box bracket for containing the finished gloves, wherein one end of the transition box bracket is provided with an outer guide tail while the other end is provided with a transition box driving mechanism and a glove block driving mechanism. The transition box driving mechanism is configured to push the glove transition box into the packaging boxes and the glove block driving mechanism is configured to block the gloves so that they remain in the packaging boxes. This packaging machine involves the operation of pushing the gloves into the packaging boxes. When the gloves are pushed into the packaging boxes, the packaging boxes may be torn due to the friction generated with any contact surface during its travel into the packaging boxes. Moreover, the gloves may be messy and bulky within the packaging boxes which may cause difficulties in closing the flaps of the packaging boxes. As a result, the packaging boxes obtained are bulky and bulgy.
Accordingly, it would be desirable to provide a method and a system for automated packaging of a stack of flexible articles into an erected box without bulging the flexible articles and damaging the erected box. The proposed invention provides such a method and a system for packaging the stack of flexible articles that solves the above-mentioned problems.
In accordance with one aspect of the present application, there is provided an automated method for packaging a stack of flexible articles, wherein the method comprises the steps of loading, by a pair of end effectors, the stack of flexible articles into an erected box having a first open end and a second open end, wherein each open end has at least one flap that is movable between an open configuration where the flap is not covering an opening of the open end and a closed configuration where the flap covers the opening of the open end, whereby the stack of flexible articles is loaded in an offset position away from the first open end, leaving a first gap therebetween, moving, by a first flap closing mechanism, the flap of the first open end from the open configuration to the closed configuration, pushing, by a pushing mechanism, the stack of flexible articles towards the first gap, thereby forming a second gap between the second open end and the stack of flexible articles and moving, by a second flap closing mechanism, the flap of the second open end from the open configuration to the closed configuration, wherein the first and second gaps are configured to prevent the flaps from being obstructed by the stack of flexible articles while closing the flaps.
According to a feature of this aspect of the present application, loading of the stack of flexible articles into the erected box may further include the steps of extending the pair of end effectors from an opposite direction towards each other so that they are in close contact with each other, loading, by a loading means, the stack of flexible articles into a slot formed by the pair of end effectors when they are in close contact, holding, by the pair of end effectors, each opposing end of the stack of the flexible articles and retracting both end effectors in two opposite directions upon loading of the stack of flexible articles within the erected box.
According to another feature of this aspect of the present application, the first flap closing mechanism can be arranged in a horizontal position with respect to a longitudinal axis of the erected box for closing the flaps of the first open end.
According to another feature of this aspect of the present application, the automated method may further comprise the step of re-orientating, by a flipping mechanism, the erected box with a closed first end from a horizontal position to an upright position so that the second open end is facing upward to receive a flap closing operation from the second flap closing mechanism that is arranged in a vertical position with respect to the longitudinal axis of the erected box.
According to another feature of this aspect of the present application, the pushing mechanism may include a plate member that is extendable and retractable along the opening of the second open end, configured to engage with the stack of flexible articles within the erected box and push them towards the first gap.
According to another feature of this aspect of the present application, the erected box can be transferred from one mechanism to another mechanism by one or more controlled arm which is configured to clamp and lift the erected box.
According to another feature of this aspect of the present application, the controlled arm may include a gripping member that is movable within predetermined directions and orientations for clamping, lifting and transferring the erected box.
According to another feature of this aspect of the present application, the first and second flap closing mechanisms may include a plurality of push members that are extendable and retractable in their position for closing the flaps, whereby the plurality of push members are arranged in an array along a pathway of a flap closing station.
In accordance with another aspect of the present application, there is provided an automated system for packaging a stack of flexible articles, wherein the system comprises a pair of end effectors for loading the stack of flexible articles into an erected box having a first open end and a second open end, wherein each open end has at least one flap that is movable between an open configuration where the flap is not covering an opening of the open end and a closed configuration where the flap covers the opening of the open end, whereby the stack of flexible articles is loaded in an offset position away from the first open end, leaving a first gap therebetween, a first flap closing mechanism for moving the flap of the first open end from the open configuration to the closed configuration, a pushing mechanism for pushing the stack of flexible articles towards the first gap, thereby forming a second gap between the second open end and the stack of flexible articles and a second flap closing mechanism for moving the flap of the second open end from the open configuration to the closed configuration, wherein the first and second gaps are configured to prevent the flaps from being obstructed by the stack of flexible articles while closing the flaps.
According to a feature of this aspect of the present application, the pair of end effectors can be configured to extend in an opposite direction towards each other so that they are in close contact with each other to form a slot for receiving the stack of flexible articles.
According to another feature of this aspect of the present application, the pair of end effectors can be further configured to hold each opposing end of the stack of the flexible articles and retract in two opposite directions upon loading of the stack of flexible articles within the erected box.
According to another feature of this aspect of the present application, the first flap closing mechanism can be arranged in a horizontal position with respect to a longitudinal axis of the erected box for closing the flaps of the first open end.
According to another feature of this aspect of the present application, the automated system may further comprise a flipping mechanism for re-orientating the erected box with a closed first end from a horizontal position to an upright position so that the second open end is facing upward to receive a flap closing operation from the second flap closing mechanism that is arranged in a vertical position with respect to a longitudinal axis of the erected box.
According to another feature of this aspect of the present application, the pushing mechanism may include a plate member that is extendable and retractable along the opening of the second open end, configured to engage with the stack of flexible articles within the erected box and push them towards the first gap.
According to another feature of this aspect of the present application, the automated system may further comprise one or more controlled arm configured to transfer the erected box from one mechanism to another mechanism.
According to another feature of this aspect of the present application, the controlled arm may include a gripping member that is movable within predetermined directions and orientations for clamping, lifting and transferring the erected box.
According to another feature of this aspect of the present application, the first and second flap closing mechanisms may include a plurality of push members that are extendable and retractable in their position for closing the flaps, whereby the plurality of push members are arranged in an array along a pathway of a flap closing station.
One skilled in the art will readily appreciate that the present application is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments described herein are not intended as limitations on the scope of the present application.
For the purpose of facilitating an understanding of the present application, there is illustrated in the accompanying drawing the preferred embodiments from an inspection of which when considered in connection with the following description, the present application, its construction and operation and many of its advantages would be readily understood and appreciated.
The present application will now be described in greater detail, by way of example, with reference to the drawings.
The packaging system generally comprises a pair of end effectors 1 configured to load the stack of flexible articles 200 into the erected box 100, a first flap closing mechanism 4 configured to seal the first open end 101 by moving the flap 103, 104, 105 from the open configuration to the closed configuration, and a second flap closing mechanism 6 configured to seal the second open end 102 by moving the flap 106, 107, 108 from the open configuration to the closed configuration. There is also provided a collecting station 7 configured to receive sealed erected box 100. The collecting station 7 preferably includes a surface that is tilted at a predetermined angle in such a way that the sealed erected box 100 is slidable on the surface. Additionally, the packaging system further comprises one or more controlled arms 3, 5 configured to transfer the erected box 100 from one mechanism to another mechanism. A conveying track 2 is provided to transfer the erected box 100 from an erecting station to a loading station and a flap closing station.
Referring to
Referring to
Referring to
Referring back to
In one embodiment of the present application, the loading operation is conducted such that when the stack of flexible articles 200 is held by the pair of end effectors 1a, 1b, the stack of flexible article 200 is loadable into the erected box 100 whilst maintaining substantially the same distance between both the end effectors 1a, 1b to prevent bulging of the flexible articles 200 during loading into the erected box 100. In this particular embodiment, the pair of end effectors 1a, 1b may have a sensing unit that ensures both the end effectors 1a, 1b are spaced apart at the same distance during its travel along into the erected box 100. By way of example, the sensing unit may be an infrared sensor that detects the distance between both end effectors 1a, 1b. After the pair of end effectors 1a, 1b have retracted to a predetermined distance, the stoppers 25a, 25b will also retract in two opposite directions away from the stack of flexible articles 200.
Referring to
In one particular embodiment, each open end 101, 102 of the erected box 100 has more than one flaps, including two inner flaps 104, 107 and two outer flaps 103, 105, 106, 108. Both first and second flap closing mechanisms 4, 6 include a plurality of push members 14, 15, 18, 19 that are extendable and retractable in their positions for closing the flaps 103, 104, 105, 106, 107, 108 whereby the plurality of push members 14, 15, 18, 19 are arranged in an array along a pathway of the flap closing station. By way of example, a first push member 14, 18 of the first and second flap closing mechanisms 4, 6 may comprise two elongate rods connected in a form of a scissor assembly where a distance between both distal ends of the elongate rods is of at least a width of the open end 101, 102, particularly a distance between both the inner flaps 104, 107. The first push members 14, 18 are configured to move along the longitudinal axis of the erected box 100, parallel to the first and second open ends 101, 102 for engaging with the inner flaps 104, 107 and moving them from the open configuration to the closed configuration simultaneously. The first push member 14, 18 of the first and second flap closing mechanisms 4, 6 may further comprise one or more push plates having a flat surface for moving a first outer flap 103, 106 of the open end 101, 102 of the erected box 100 from the open configuration to the closed configuration. Furthermore, a second push member 15, 19 of the first and second flap closing mechanisms 4, 6 which is preferably arranged beside the first push members 14, 18 may comprise one or more push plates having a flat surface for moving a second outer flap 105, 108 of the open end 101, 102 from the open configuration to the closed configuration to fully cover the opening of the first and second open ends 101, 102 of the erected box 100. Additionally, the first outer flap 103, 106 further includes an inwardly folded flap 109 at its end which can be formed by a folding member 13, 17 of the first and second flap closing mechanisms 4, 6, whereby the inwardly folded flap 109 is configured to slip into the erected box 100 when the first outer flap 103, 106 is pushed to the closed configuration.
The packaging system further comprises a flipping mechanism that is arranged in between the first and second flap closing mechanisms 4, 6, configured to re-orient the erected box 100 with a closed first open end 101 from a horizontal position to an upright position so that the second open end 102 is facing upward to receive a flap closing operation from the second flap closing mechanism 6 that is arranged in the vertical position with respect to a longitudinal axis of the erected box 100. Preferably, the flipping mechanism comprises a platform 20 configured to allow the erected box 100 to rest thereon in its horizontal position. The platform 20 can be actuated by an actuator 21 to be lifted up from an initial horizontal position to an upright position which this subsequently flips the erected box 100 that is resting on the platform 20. Additionally, the packaging system further comprises a pushing mechanism 16 that is arranged in a vertical position at the flap closing station with respect to the longitudinal axis of the erected box 100 and is installed after the flipping mechanism and before the second flap closing mechanism 6. The pushing mechanism 16 is configured to push the stack of flexible articles 200 towards the first gap, thereby forming a second gap between the second open end 102 and the stack of the flexible articles 200. Advantageously, this pushing operation by the pushing mechanism 16 is to discharge trapped air from the stack of flexible articles. Furthermore, the second gap ensures a smooth flap closing operation as it prevents the flaps 106, 107, 108 of the second open end 102 from being obstructed by the stack of flexible articles 200 when closing the flaps 106, 107, 108. Preferably, the pushing mechanism 16 includes a plate member that is extendable and retractable in a vertical direction along the opening of the second open end 102, configured to engage with the stack of flexible articles 200 within the erected box 100 and push them towards the first gap to form the second gap.
The packaging system further comprises one or more controlled arms 3, 5 for transferring the erected box 100 loaded with the stack of flexible articles 200 from one mechanism to another mechanism. By way of example, a first controlled arm 3 is configured to clamp and lift the erected box 100 from the conveyor track 2 and direct the first open end 101 of the erected box 100 to the first flap closing mechanism 4 to receive the flap closing operations from each push member 14, 15. Furthermore, the first controlled arm 3 is configured to place the erected box 100 with the closed first open end 101 on the flipping mechanism. A second controlled arm 5 is configured to transfer the re-oriented erected box 100 to the second flap closing mechanism 6 to receive the flap closing operations from each push member 18, 19. Preferably, the controlled arms 3, 5 may include a gripping member that is movable within predetermined directions and orientations for clamping, lifting and transferring the erected box 100. The second controlled arm 5 is further configured to transfer the erected box 100 obtained from the second flap closing mechanism 6 to the collecting station 7.
By way of example, the erected box 100 described herein is in an interlock tucking type, as shown in
In a further aspect of the present application, the packaging system can be used for executing a series of steps to package the stack of flexible articles 200 into the erected box 100. Referring to
Referring to
The present disclosure includes as contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangements of parts may be resorted to without departing from the scope of the present application.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021003212 | Jun 2021 | MY | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CN2021/126826 | 10/27/2021 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2022/257333 | 12/15/2022 | WO | A |
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| Number | Date | Country |
|---|---|---|
| 202728596 | Feb 2013 | CN |
| 208053757 | Nov 2018 | CN |
| 211618333 | Oct 2020 | CN |
| 112623356 | Apr 2021 | CN |
| 1280760 | Jul 1972 | GB |
| 2019221594 | Nov 2019 | WO |
| Entry |
|---|
| International Search Report—PCT/CN2021/126826 dated Mar. 10, 2022. |
| PCT Written Opinion—PCT/CN2021/126826 issued on Mar. 10, 2022, citing CN 208053757. |
| Indian Office Action—Indian Application No. P00202211349 issued on Jan. 29, 2024, citing CN208053757U, CN211618333U, CN112623356A, GB1280760A, and WO2019221594A1. |
| Number | Date | Country | |
|---|---|---|---|
| 20240101290 A1 | Mar 2024 | US |
