Patent Application
20240391624
The present invention relates to the sector of the packing of packages of articles and, in detail, the sector of packing of units of packages; preferably, through not exclusively, of single-dose packages of comestible articles.
More specifically the invention relates to a method, a system and a computer program for forming units of packages to be packed, and is especially applicable in the services of boxing machines or packaging machines.
In a common practice, in the terminal part of the production lines, the articles are first packaged and then the packages are grouped together, thus forming units i.e. one or more groups of two or more packages arranged in an ordered way, as compact as possible and ready for the successive step of packing. These steps are generally managed at high velocity, i.e. with high frequencies of packages grouped and then packed so as not to impact negatively on upstream processes. In general the frequencies increase in the case of single-dose packages.
In these steps checks are often carried out on the articles and/or on the packages, which might lead to rejects which affect the flow of packages; the flow can also be affected by malfunctions, in both the terminal part of the production line and upstream.
The grouping of packages must necessarily take account of these eventualities in order to avoid having units, and therefore packs, with a number of packages that is different to the desired number. Whenever packages from a single line are grouped, the rejects and/or malfunctions are generally managed by waiting for the unit to complete or for a sub-multiple of the unit, which when joined with other sub-multiples will form the unit, completes. The same approach can be replicated in a case of a plurality of inlet lines, the packages of which are groupable independently, for example when the packages from every inlet line are loaded onto a relative outlet line. Instead, the management of the rejects and/or the malfunctions becomes complicated when two or more lines are inter-related with one another, typically when the packages thereof must be loaded onto a same outlet line. When the waiting times of the packages of a line cannot be managed independently of the waiting times of the packages of at least one other line, one of the inlet lines can supply a wrong number of packages causing, without corrective actions, a unit, and therefore a package, that is incorrect. In general, in packs, one or more packages are lacking.
The corrective actions of known type operate according to two opposite approaches. The incomplete groups, i.e. a number of packages that is smaller than desired, are rejected or reintegrated, adding a number of packages equal to the missing number from a reintegrating store. Neither solution is without drawbacks: in the first case not all the packages in arrival are packed, while in the second case it is necessary to load the store with packages.
A first aim of the present invention is to ensure a correct unit of the packages from two or more lines so as to avoid packs with an erroneous number of packs.
A second aim is to guarantee the processing, i.e. the successive packing, of the packages in arrival without rejects i.e. processing all the arriving packages. Another aim is to obviate the issues of the prior art solutions.
An aim of some embodiments is not to request or require limited loading operations of the reintegrating store. A further aim of some embodiments is to guarantee the processing operations of the packages without significant differences between the flow in arrival and the flow in outlet, i.e. between the sequence of packages in arrival and the sequence of packages in outlet.
A further aim of some embodiments is to provide a system for forming units of packages which is particularly rapid, while guaranteeing a high level of reliability. These and other aims, which will be obvious to the expert in the sector from a reading of the following text, which follows, are attained by means of a method for forming units according to claim 1, by means of a system according to claim 6 or by means of a computer program according to claim 14.
In accordance with the teachings of the present document, the method comprises steps of:
During the step of correcting the number of packages, packages are advantageously moved from the seats to the store and vice versa, so that the number of packages in each seat is equal to the number n or to zero.
Further, during the step of transferring the packages, the compartments are made available on the basis of the seats with a number of packages equal to the number n, i.e. regardless of the seats with a number of packages equal to zero, so that each compartment receives a unit comprising a multiple of a number n of packages.
In accordance with the teachings of the present document, the system comprises:
The displacement means are advantageously also configured to displace the packages from the seats to the at least a depot and the control and command means are configured so that the number of packages in each seat is equal to the number n or to zero. Further, the movement means are configured to make the compartments available in sequence on the base of the seats with a number of packages equal to the number n, so that each compartment receives a unit comprising a multiple of a number n of packages.
In accordance with the teachings of the present document, the system can realise the method with the use of a computer program.
The teachings of the present invention enable correction of previous errors and/or rejects so as to prevent the formation of units, and therefore of packs, with an incorrect number of packages, i.e. with a number of packages that is different to a predetermined multiple of numbers n of packages, i.e. n packages, 2n packages, 3n packages, etc.
Specific embodiments of the invention will be described in the following part of the present description, according to what is set down in the claims and with the aid of the accompanying drawings, in which:
With reference to the appended drawings, reference numeral 100 denotes a system for forming units (B) of packages (A) to be packed, each unit (B) comprising a multiple of a number n of packages (A). As the number n represents a plurality of packages, obviously the number n is a natural number greater than 1. An embodiment of the system (100) comprises:
The stacks of packages (A) loaded in each seat (1) of a group of two or more seats (1) can have a number of packages (A) different to one another, the control and command means (7) correct the seats (1) which bear a stack of packages (A) with a number of packages (A) that is different to the number n.
In the system (100) according to the invention:
In accordance with the teachings of the invention the store (2) can also receive packages (A), so as to transfer the packages (A) from a seat (1) which has been loaded erroneously, and the system (100) manages the presence of seats (1) without packages (A). The system (100) of the invention thus avoids rejects and reduces or, possibly, eliminates the need to refill the store (2).
The compartments (61) can be a part of the system (100), such as for example in the case of the embodiment of
The transfer means (5) can transfer packages (A) into each compartment (61) from a plurality of seats (1), so as to form a unit (B) comprising a multiple of a number n of packages (A).
In general, also the depots (21, 22, 23, 24) are designed to accommodate packages (A) in a stack.
The control and command means (7) generally comprise a programmable logic controller (71), shown by way of example in the guise of a cabinet in
The store (2) preferably comprises a plurality of depots (21, 22, 23, 24) and the displacement means (4) of the packages (A) are configured so as to be able to move packages (A) from each depot of the plurality of depots (21, 22, 23, 24) to each of the seats (1) of each group of two or more seats (1).
This characteristic advantageously enables reducing the disparity in the filling of the depots (21, 22, 23, 24) due to the different number of packages (A) loaded in each seat (1), preventing one depot (21, 22, 23, 24) from accumulating many more packages (A) than the others. Further it enables reducing the change of order of the packages (A), between the inlet and outlet of the system (100), thus guaranteeing units (B) as homogeneous as possible. For example, this prevents packages (A) remaining for a long time in the depot (21, 22, 23, 24) from mixing with packages (A) produced long after since the depot (21, 22, 23, 24) exclusively serves a line in which rejects are rare.
Typically, each seat (1) of a group of two more seats (1) is loaded with a respective stack of packages (A) in arrival from a line of two or more lines (C).
The system (100) preferably comprises a transporter (10) that moves the seats (1) from a loading zone (11) of the packages (A) to a transfer zone (12) of the packages (A) according to a movement direction (M).
Further:
More preferably:
The stepped movement of the transporter (10) facilitates the loading of the seats (1) with stacks of packages (A) and/or the transfer of the packages (A) to the compartments (61): in fact these operations can take place between one step and the next. Reducing the number of pickups at each step advantageously accelerates the movement of the seats (1) towards the transfer zone (12): the transfer means (5) do not have to wait for a plurality of movements of the pick-up elements (41, 42, 43, 44) before receiving the successive seat (1).
In this way the waiting time between groups of two or more seats (1) in arrival in the loading zone (11) is kept to a minimum.
In order to be able to manage all possibilities, the store (2) must comprise a number of depots (21, 22, 23, 24) which enable the correction of the seats (1), regardless of the number of seats (A) they bear. In the preferred case, in which each seat bears at most a number n of packages (A) and in which each of the pick-up elements (41, 42, 43, 44) displaces at most one package (A) at each step of the transporter (10), this condition takes place with a number of depots (21, 22, 23, 24) that is greater than or equal at least to the whole part of half the number n. For example, at least one depot is required in the minimum condition of number n of packages (A), being two which in the case of the number n of packages (A) is three; at least two depots are required if the number n of packages (A) is five, so as to operate in the worst conditions in which the stack of packages (A) has been loaded with two or three packages (A).
More preferably, the store (2) comprises a number of depots (21, 22, 23, 24) equal at least to the number n minus one, i.e. greater than or equal to number n−1. A system (100) as described above is capable of correcting any seat (1) with a number of packages (A) equal to the number n, also in the case where the store (2) is completely unloaded or in any case has a number of packages (A) that is smaller than the difference between the number n and the number of packages (A) in the seat (1).
This translates into two advantages: it is no longer necessary to load the store (2) at the start of the operations, with obvious operating advantages, and it is not necessary to have available packages (A) in the store (2) during operation. It is thus possible to keep the store (2) practically empty, with the consequent advantages as already described in terms of reduced variations in the sequence of the packages (A), i.e. the variations in the order of the packages (A) between the inlet and outlet are reduced.
By way of example, the embodiment of
As can be observed for example in
In a preferred operating mode, the pick-up elements (41, 42, 43, 44) are moved in unison if the displacement of at least a package (A) is required; this minimises wear on the displacement means (4). In a further preferred operating mode, the pick-up elements (41, 42, 43, 44) move from the depot (21, 22, 23, 24) to the seats (1), and vice versa, at each step of the transporter (10); the number of packages (A) in the seats (1) is thus relevant only for activation thereof.
The loading means (3) preferably comprise two or more wings (32, 33, 34, 35), each for supporting packages (A). For example,
These positions are shown respectively in
The lines (C) in arrival, schematically represented with the portions of track in only
Often the lines (C) in inlet are synchronous, i.e. they supply packages (A) with the same cadence, except for errors due to checks and/or errors. The phased supply of the packages (A) facilitates the loading of an outlet line from a plurality of inlet lines (C) but is not strictly necessary, as long as the timings or the elements present enable this operation.
The system (100) preferably comprises phasing means to phase the packages (A) from two or more lines (C) so that the loading means (3) receive the packages (A) simultaneously from the two or more lines (C). For example, with reference to
The phasing means facilitate the management of the two or more lines (C) as they guarantee the synchronous inlet of the packages (A) into the drawers (37). In fact the loading means (3) no longer work on the basis of the arrival of the single package (A), but in rows, i.e. by successive groups of packages (A) made up of a single package (A) for each of the two or more lines (C), unless in the case of rejects or malfunctions that cause the absence of the package (A) in each of the two or more lines (C) involved. The teachings of the invention enable effective management of empty places in the rows.
As for example can be seen in
The transfer means (5) preferably comprise a pusher (51) for pushing the packages (A) of a seat (1) when located in the transfer zone (12). The pusher (51) is movable in a pushing direction (P), transversal to the movement direction (M), between a retracted position and an extracted position. In the movement between the two positions the pusher (51) pushes the packages (A) that might be present in the seat (1) into the compartment (61).
The transporter (10) is advantageously configured so as to be stationary when the two or more wings (32, 33, 34, 35) are in the second position and the pusher (51) is configured so as to move towards the extracted position between two steps of the transporter (10). In this way the transporter (10) is stationary when the two or more wings (32, 33, 34, 35) unload the stacks of packages (A) and when the pusher (51) pushes the packages.
In general the transporter (10) performs groups of steps equal to the number of stacks of packages (A) supported by the two or more wings (32, 33, 34, 35) and then pauses to enable the stacks of packages (A) to fall into the seats (1). The pusher (51) can be moved downstream of each step or only when it is adjacent to a seat (1) with packages (A).
In a case where the compartments (61) are a part of the system (100), the movement means (6) preferably comprise a conveyor belt (62) which bears groups of two or more compartments (61) arranged in a line, according to the direction in which they are made available. For example,
In a case where the compartments are not a part of the system, for example they are boxes, the movement means can comprise conveyors or the like for the movement thereof.
The movement means (6) are preferably configured to make available one compartment (61) alone, between two seats (1) with a number of packages (A) equal to the number n, so that each group of two or more compartments (61) forms a unit (B) of packages (A) comprising a number of packages (A) equal to the product of number n and of the number of compartments (61) made available.
Each unit (B) of packages (A) thus-formed can be translated onto the bundle forming plane and, successively, compacted or taken directly into a boxing machine. The packages (A) might, for example, be sachets which contain tea, coffee, sugar, cocoa or other products, including non-comestibles.
The invention also relates to a method for forming units (B) of packages (A) to be packed, each unit (B) comprising a multiple of a number n of packages (A), with the packages (A) in arrival from two or more lines (C) which operate contemporaneously.
The teachings of the method preferably though not exclusively apply to a system (100) such as the one described above. Further, the above specification, for example relative to the number n of compartments (61) or lines (C), are also valid concerning the method.
In an embodiment the method comprises steps of:
The step of learning the number of packages (A) can be done in various ways, for example by receiving the datum directly from the lines (C), or making a count on arrival from the lines (C), or after. By way of example the count can be done during the passage of the packages (A) in the field of action of the photocells (72) or scales.
During the step of correcting the number of packages (A), packages (A) are advantageously moved from the seats (1) to the store (2) and vice versa, so that the number of packages (A) in each seat (1) is equal to the number n or to zero. Further, during the step of transferring the packages (A), the compartments (61) are made available on the basis of the seats (1) with a number of packages (A) equal to the number n, i.e. regardless of the seats (1) with a number of packages (A) equal to zero, so that each compartment (61) receives a unit (B) comprising a multiple of a number n of packages (A).
The method of the invention enables transfer of the packages (A) without rejects, i.e. it guarantees the processing of all the packages (A) in arrival from the two or more lines (C). Further, with the bi-directional nature of the displacement in the step of correcting the number of packages (A), the demand for supply to the store (2) is reduced or eliminated.
The empty seat (1) has no influence on the performance of the machine actuating the method, in the sense that no package is rejected in the ambit of a no product no bag operating logic. In fact, the loss of performance occurs when a number of packages (A) is packed that is smaller than the number supplied.
During the step of forming groups of two or more stacks of packages (A) in succession, each group is preferably completed when at least a stack of packages (A) comprises a number n of packages (A) equal to the number n. In this way it is guaranteed that at least a stack of packages (A) is already prepare to be transferred; in the case of lines (C) in arrival with an identical cadence or with packages (A) placed in phase during the step of forming groups of two or more stacks of packages (A) in succession, the stacks of packages (A) all tend to have a number n of packages (A) excluding rejects and/or errors. Thus the number of operations required is limited during the step of correcting the number of packages (A) and/or it is not necessary to accumulate packages (A) in the store (2).
During the step of transferring the packages (A), one compartment (61) alone, between two seats (1), is preferably made available with a number of packages (A) equal to the number n, regardless of the number of seats (1) interposed there-between, with a number of packages (A) equal to zero, so that a sequence of compartments (61) houses a unit (B) of packages (A) comprising a number of packages (A) equal to the product of number n and of the number of compartments (61) made available.
Preferably, in the step of correcting the number of packages (A), should the number of packages (A) in the seat (1) be lower than n:
The use of the store (2) is advantageously reduced and the tendency is to unload it; some advantages result from this. Firstly, the reaching of the limit of packages (A) that the store (2) can collect is avoided. Secondly, the times that would be required to use up the packages (A) in the store (2) are reduced, when the two or more lines (C) stop operating. Thirdly, the greater the number of packages (A) in the store (2), the greater the variation in the order of the packages (A), between inlet and outlet. For example, the order might be important if there emerges a non-conformity of a part of the packages (A), due to a process upstream.
The number of packages (A) collectable from the store (2) depends on many factors; for example, with reference to the embodiment of
The step of forming groups of two or more stacks of packages (A) in succession preferably comprises a preliminary step of:
In this way the step of supplying in succession groups of two or more seats (1), as described in the foregoing, is facilitated.
The invention also relates to a computer program for forming units (B) of packages (A) to be packed, each unit (B) comprising a multiple of a number n of packages (A), with the packages (A) in arrival from two or more lines (C) which operate contemporaneously. In an embodiment the program comprises instructions for control of the system (100) according to the invention, as described in the foregoing, so as to carry out the method of the invention, as described in the foregoing.
In order to further clarify the strict correlation between the method and the system (100) described above,
In
The third stack of packages (A) crosses the displacement means (4) without being affected by displacements of packages (A). The fourth stack is instead corrected with the packages (A) just moved into the store (2) from the second stack of packages (A); this can be observed especially in
It is important to stress how the pusher (51) of the transfer means (5) is in the extracted position in
In the operating example the transporter (10) realises one step at a time and the displacement means (4) realise at most a pick-up for each seat (1) flanked to a depot (21, 22, 23, 24). By comparing the operating example of
It is understood that the above has been described by way of non-limiting example and that any constructional variants are considered to fall within the protective scope of the present technical solution, as claimed in the following.
