This invention relates generally to container sizing and particularly to systems, methods, devices and tools for sizing containers. More specifically, although not exclusively, this invention relates to modifying the size of a box or carton to suit its contents.

One application in which carton sizing devices are particularly useful is in the field of made-to-order packages, wherein orders are placed for varying product types and quantities and packages containing such products must be prepared for shipment. These applications result in an infinite number of combinations of products that are placed in standard sized cartons and so they occupy varying heights and volumes within such cartons. Package shipment costs are generally dependent upon both the weight and dimensions of the package to be shipped. The wide variation in filling level often results in a void at the top of the carton, requiring additional packing material, leading to waste, and unnecessarily large carton sizes, leading to higher shipping costs.

Known solutions to this issue involve the use of a single carton blank size that is modified in some way to suit the contents to be packed. EP0645309, for example, discloses a cartoning system in which the erected carton is cut to a height equivalent to the contents to be packed and a separate lid placed on the open top, which results in wasted material. FR2612885 proposes a carton blank in which upper panels are foldable at one of a plurality of fold lines, thereby providing limited adaptability, requiring bespoke carton blanks which can be expensive and causing problems in the erection and closure of the cartons in use. FR2606367 discloses a cartoning system in which carton blanks are creased before erection and filling based on known content configurations, which requires prior knowledge of the contents to be packed and therefore lacks adaptability. US3953956 describes a cartoning system in which a prefilled open top carton is scored at the height of the contents and vertical corners are cut down to the level of the score lines to create flaps to be closed, but reconfiguration of the system to accommodate different carton sizes is an involved process.

WO2013182845 filed by the present applicants seeks to provide a container sizing device that is particularly suited to made-to-order packaging applications by determining the footprint of a partially filled open top carton and the height of its contents using a vision system and then positioning cutters and markers based on the determined footprint to cut and crease the carton. Whilst the arrangement disclosed in this document performs very well, the applicants have determined that the repositioning of the cutters and markers could be improved to reduce adjustment and/or cycle time.

It is therefore a first non-exclusive object of the invention to provide an improved means of adapting the configuration of cutters and markers to accommodate different carton footprints and fill levels. It is a further non-exclusive object of the invention to provide a simpler and more cost-effective means of cutting and creasing cartons. It is a yet further, more general non-exclusive object of the invention to provide an improved system, method, device and tool for sizing containers.

Accordingly, a first aspect of the invention provides a container or carton sizing system or apparatus comprising a frame, a controller, a marking device movably mounted to the frame and operatively connected to the controller and measuring means operatively connected to the controller and configured to determine, in use, the height of one or more objects contained within an open top carton, wherein the controller is configured to position the marking device based on the determined height and to score or crease, e.g. simultaneously, adjoining first and second vertical walls of the carton, e.g. using the marking device, to define at least part of a foldable panel in each of the first and second walls.

The provision of a marking device that scores or creases two adjoining vertical walls simultaneously can reduce the cycle time required to form the carton.

The system or apparatus may comprise two or more marking devices movably mounted to the frame and operatively connected to the controller. The controller may be configured to position a first of the marking devices based on the determined height and/or to form a first score or crease from a first vertical edge of a vertical wall of the carton across a first part of the width of the wall. The controller may be configured to position a second of the marking devices based on the determined height and/or to form a second score or crease from a second vertical edge of the wall across a second part of its width, e.g. before, during or after the positioning of and/or scoring or creasing by the first marking device. The first and second scores or creases may together define a foldable panel in the vertical wall. Another aspect of the invention provides a container or carton sizing system or apparatus comprising a frame, a controller, two or more marking devices movably mounted to the frame and operatively connected to the controller and measuring means operatively connected to the controller and configured to determine, in use, the height of one or more objects contained within an open top carton, wherein the controller is configured to position a first of the marking devices based on the determined height and to form a first score or crease from a first vertical edge of a vertical wall of the carton across a first part of the width of the wall and to position, e.g. to then position, a second of the marking devices based on the determined height and to form a second score or crease from a second vertical edge of the wall across a second part of its width, wherein the first and second scores or creases together define a foldable panel in the vertical wall.

The provision of two marking devices that each score or crease part of the width of the vertical walls of the carton enables the system to be adjusted easily to accommodate cartons having different footprints by simply moving the marking devices relative to one another. For the avoidance of doubt, the first and/or second parts of the width of the wall may extend from the first vertical edge to the second vertical edge, for example where the system or apparatus is configured to accommodate the smallest cartons in a predetermined carton size range.

The first marking device may be configured to score or crease adjoining first and second vertical walls of the carton. The second marking device may be configured to score or crease adjoining second and third vertical walls of the carton, for example such that a foldable panel is defined in the second wall of the carton in part by each of the scores or creases formed by each of the first and second marking devices.

Another aspect of the invention provides a container or carton sizing system or apparatus comprising a frame, a controller, two or more marking devices movably mounted to the frame and operatively connected to the controller and measuring means operatively connected to the controller and configured to determine, in use, the height of one or more objects contained within an open top carton, wherein the controller is configured to position a first of the marking devices based on the determined height and to score or crease adjoining first and second vertical walls of the carton and to then position a second of the marking devices based on the determined height and to score or crease adjoining second and third vertical walls of the carton such that a foldable panel is defined in the second wall of the carton in part by each of the scores or creases formed by each of the first and second marking devices.

The system or apparatus may comprise three or more marking devices, each of which may be movably mounted to the frame and/or operatively connected to the controller. The controller may be configured to position a third marking device based on the determined height. The controller may be configured to score or crease, or to cause to be scored or creased, adjoining third and fourth vertical walls, e.g. using the third marking device, for example such that a foldable panel is defined in the third wall of the carton in part by each of the scores or creases formed by each of the second and third marking devices.

The system or apparatus may comprise four or more marking devices, each of which may be movably mounted to the frame and/or operatively connected to the controller. The controller may be configured to position a fourth marking device based on the determined height. The controller may be configured to score or crease, or to cause to be scored or creased, adjoining first and fourth vertical walls, e.g. using the fourth marking device, for example such that a foldable panel is defined in the first wall of the carton in part by each of the scores or creases formed by each of the first and fourth marking devices and/or such that a foldable panel is defined in the fourth wall of the carton in part by each of the scores or creases formed by each of the third and fourth marking devices.

The first marking device may be configured to score or crease the first and second vertical walls substantially simultaneously. The second marking device may be configured to score or crease the second and third vertical walls substantially simultaneously. The third marking device may be configured to score or crease the third and fourth vertical walls substantially simultaneously. The fourth marking device may be configured to score or crease the first and fourth vertical walls substantially simultaneously. Each marking device may be configured to crease the adjoining walls simultaneously.

The controller may be configured to position the first and third marking devices substantially simultaneously and to score or crease the first, second, third and fourth vertical walls substantially simultaneously. Additionally or alternatively, the controller may be configured to position the second and fourth marking devices substantially simultaneously and to score or crease the first, second, third and fourth vertical walls substantially simultaneously.

The frame may comprise a gantry and/or first subframe and/or a second subframe. The first and third marking device may be mounted to the first subframe and/or movable together. The second and fourth marking device may be mounted to the second subframe and/or movable together.

At least one or each of the marking devices may comprise a pair of opposed forming tools. At least one or each of the forming tools may include a pair of, for example first and second, forming portions, e.g. a respective pair or respective first and second forming portions. The first and second forming portions, e.g. of each forming tool, may extend at a right or oblique angle relative to one another. The controller may be configured to cause the tools to move relative to one another, for example toward one another, e.g. thereby causing a portion of one of the adjoining vertical walls to be scored or creased between the first forming portions and/or causing a portion of the other of the adjoining vertical walls to be scored or creased between the second forming portions.

A yet further aspect of the invention provides a container or carton marking device comprising a pair of opposed forming tools each with respective first and second forming portions extending at a right or oblique angle relative to one another, wherein the tools are configured to receive, in use, a portion of two adjoining walls of a carton therebetween such that movement of the tools toward one another causes the first forming portions to score or crease the first carton wall therebetween and the second forming portion to score or crease the second carton wall therebetween.

Another aspect of the invention provides a container or carton cutting device comprising a cutter and a guide for receiving portions of adjoining first and second vertical walls of a carton with the cutter in alignment with the vertical edge of the carton between the first and second vertical walls, wherein the guide is configured to guide the cutting device along the vertical edge such that the cutter cuts the vertical edge.

The cutting device may comprise any one or more features of the marking devices mentioned above. The guide may comprise one or more features of the first and/or second forming portions. The first forming portion of one of the forming tools may comprise a blade or blade portion or member and/or the first forming portion of the other of the forming tools may comprise an anvil or anvil portion or member. The second forming portion of one of the forming tools may comprise a blade or blade portion or member and/or the second forming portion of the other of the forming tools may comprise an anvil or anvil portion or member. At least one or each forming tool may comprise a forming member that includes the first and second forming portions. In some embodiments, the first and second forming portions are substantially orthogonal relative to one another or they extend at a substantially right angle relative to one another, e.g. for scoring or creasing a carton having a square footprint. In other embodiments, the first and second forming portions are not orthogonal relative to one another or they extend at a non-right angle relative to one another, e.g. for scoring or creasing a carton having polygonal footprint with less or more than four sides. In embodiments, the first and second forming portions may extend at an acute angle relative to one another, e.g. for scoring or creasing a carton having a triangular footprint. In embodiments, the first and second forming portions are at obtuse angles relative to one another, e.g. for scoring or creasing a carton having a polygonal with more than four sides.

In embodiments, the first and second forming portions of a first forming tool comprises a blade or blade portion or member and/or the first and second forming portions of a second forming tool comprises an anvil or anvil portion or member. The first forming tool may be configured to be positioned, in use, on the inside of the carton and/or the second forming tool is configured to be positioned on the outside of the carton or vice versa.

At least one or each of the marking devices may comprise a pair of arms that may be pivotally connected to one another and/or may have a respective one of the forming tools mounted thereto, e.g. at or adjacent a free end thereof. The arms of the or each marking device may be operable by an actuator, e.g. to move the tools relative to one another. The actuator may be connected to each of the arms, for example at or adjacent an opposite end thereof to the forming tools. The arms may be pivotally connected together at or adjacent their ends, but preferably intermediate their ends, e.g. such that operation of the actuator causes the arms to pivot thereby moving the tools relative to one another. The actuator may comprise a cylinder assembly one end of which may be connected to a respective one of the arms. The or each actuator may comprise a piston reciprocable within a cylinder, e.g. wherein one of the piston and cylinder is connected to one of the arms and/or the other of the piston and cylinder is connected to the other of the arms. The or each actuator may be driven electrically or electromechanically or electromagnetically or hydraulically or pneumatically and/or may comprise an electric or electromechanical or electromagnetic or hydraulic or pneumatic actuator.

The system or apparatus may comprise one or more cutters, e.g. for cutting a vertical edge between the adjoining vertical walls. The one or more cutters may be movable with respect to the frame, for example separately from or together with one or each of the marking devices. At least one or each of the marking devices may comprise a cutter, e.g. for cutting a vertical edge between the adjoining vertical walls. The cutter may be movable between a retracted position, e.g. in which it is at least partially concealed, and/or a deployed position, e.g. in which a cutting edge thereof is exposed. The controller may be configured to position at least one or each of the marking devices by moving it along the vertical edge, for example such that the cutter cuts the vertical edge as the marking device is moved therealong. The cutter may be positioned between the first and second forming portions of one of the forming tools, e.g. the first forming tool. In such cases, it is preferable that the first forming tool is configured to be positioned, in use, on the inside of the carton and the second forming tool is configured to be positioned on the outside of the carton.

Another aspect of the invention provides a container or carton sizing system or apparatus comprising a frame, a controller, one or more cutting devices movably mounted to the frame and operatively connected to the controller and measuring means operatively connected to the controller and configured to determine, in use, the height of one or more objects contained within an open top carton, wherein the or each cutting device comprises a cutter and a guide for receiving portions of adjoining first and second vertical walls of the carton with the cutter in alignment with the vertical edge of the carton between the first and second vertical walls, the controller being configured to move the cutting device along the vertical edge based on the determined height thereby to cause the cutter to cut the vertical edge to a position at or adjacent, e.g. above or slightly above, the measured height.

The cutting device may comprise any one or more features of the marking devices mentioned above. At least one or each of the second, third, fourth and/or any subsequent marking devices may be movable relative to the first marking devices, for example to accommodate cartons having different footprints. Additionally or alternatively, the measuring means may be configured to determine, in use, the footprint of an open top carton. The controller may be configured to move at least one or each of the second, third, fourth and/or any subsequent marking devices relative to the first marking device, e.g. based on a footprint, which may be determined by the measuring means or entered or selected by a user or operator.

The first subframe may comprise a first driving means, e.g. for moving the third marking device relative to the first subframe. The second subframe may comprise second and/or third driving means, e.g. for moving the second and/or fourth marking devices, for example respectively, relative to the second subframe and/or relative to one another. At least one or each marking device or forming tool or pair of forming tools may be movable vertically relative to the frame, for example by a vertical driving means, e.g. a respective or common vertical driving means. At least one or each of the driving means and/or at least one or each of the vertical driving means may comprise a ball screw driven by a motor. At least one or each of the motors may be driven electrically or electromechanically or electromagnetically or hydraulically or pneumatically. At least one or each of the motors may comprise an electric or electromechanical or electromagnetic or hydraulic or pneumatic motor. One or more of the motors may comprise one of the aforementioned configurations while one or more of the other motors may comprise another of the aforementioned configurations.

The system or apparatus may further comprise a folding device, which may be configured to fold, in use, one or more foldable panels formed by the marking devices. The folding device may comprise one or more folding actuators, which may comprise a cylinder assembly and/or a roller element at the end thereof. The or each folding actuator may comprise a piston reciprocable within a cylinder, e.g. with a roller element attached to the piston. The or each folding actuator may be driven electrically or electromechanically or electromagnetically or hydraulically or pneumatically and/or may comprise an electric or electromechanical or electromagnetic or hydraulic or pneumatic actuator. The folding device may comprise retaining means, e.g. for retaining a foldable panel on a vertical carton wall, e.g. while one or more other panels is or are folded by a folding actuator. The retaining means may comprise a suction feature or element or device, e.g. a pneumatic suction feature, element or device. In some embodiments, the retaining means comprises a flexible element, e.g. a suction cup, which may be operatively or fluidly connected to a vacuum means. The retaining means may comprise a tube that may be operatively or fluidly connected to the vacuum means. In some embodiments, the flexible element is operatively or fluidly connected to the vacuum means via the tube. The tube may be flexible, but is preferably rigid particularly when connected to the flexible element.

The folding device may comprise one or more pairs of opposed folding actuators, e.g. for folding a pair of foldable panels, for example each on one of a pair of opposing vertical carton walls. The folding device may comprise one or more pairs of retaining means, e.g. for retaining a pair of foldable panels, for example each on one of a pair of opposing vertical carton walls, e.g. while a pair of panels are folded by folding actuators. In some embodiments, the folding device comprises a first pair of opposed folding actuators for folding a first pair of foldable panels each on one of a first pair of opposing vertical carton walls. The folding device may comprise retaining means for retaining a second pair of foldable panels each on one of a second pair of opposing vertical carton walls while the first pair of panels are folded by the folding actuators. The folding device may comprise a second pair of opposed folding actuators for folding the second pair of foldable panels.

The folding device may comprise a frame. At least one of the folding actuators may be connected to the frame, e.g. via an arm that may be movable relative to the frame. The or each folding actuator may be connected to a free end of the arm. In some embodiments, each of the first folding actuators is mounted to a respective one of a first pair of opposed arms. Additionally or alternatively, each of the second folding actuators may be mounted to a respective one of a second pair of opposed arms. The second pair of opposed arms may each comprise a retaining means, e.g. for retaining a respective one of the second pair of foldable panels. The first and/or second pair opposed arms may be movable toward and/or away from one another, e.g. to accommodate cartons having different footprints. The first pair of opposed arms may mounted to and/or movable along a first rail and/or the second pair of opposed arms may be mounted to and/or movable along a second rail.

The system or apparatus may further comprise a carton closing device, which may include an adhesive application means, e.g. for fastening two or more foldable panels together. The adhesive application means may comprise a tape applicator or a glue applicator. The carton closing device may comprise one or more, e.g. a pair of, retaining surfaces, e.g. for retaining the uppermost foldable panels in a closed condition prior to, after or during the fastening the two or more foldable panels together by the adhesive application means. The or at least one or each of the retaining surfaces may comprise a belt or conveyor or conveyor belt.

The system or apparatus may comprise a conveying means or conveyor, e.g. a composite conveyor that may be made up of two or more conveying devices. The conveying means which may be operable or configured to move a carton, for example a carton with one or more objects therein, from an inlet of or to the system or apparatus to one or more stations thereof and/or to an outlet thereof. The system or apparatus may comprise a first station including the first and third marking devices. The system or apparatus may comprise a second station including the second and fourth marking devices. The system or apparatus may comprise a third station including the folding device. The system or apparatus may comprise a fourth station including the carton closing device.

According to another aspect of the invention, there is provided a container or carton sizing apparatus comprising a carton marking device, which may comprise one or more carton marking devices as described above.

According to yet another aspect of the invention, there is provided a container or carton sizing system or apparatus comprising a frame, a controller, one or more cutters movably mounted to the frame and operatively connected to the controller, two or more marking devices movably mounted to the frame and operatively connected to the controller and measuring means operatively connected to the controller and configured to determine, in use, the footprint of an open top container or carton and to determine the height of one or more objects contained within the container or carton, wherein the controller is arranged or configured or programmed to position the one or more cutters based on the determined footprint and to cut vertical edges of the container or carton based on the determined height, the controller being further arranged or configured or programmed to position a first of the marking devices based on the determined height and to form a first score or crease from a first vertical edge of a vertical wall of the carton across a first part of the width of the wall and to then position a second of the marking devices based on the determined height and to form a second score or crease from a second vertical edge of the wall across a second part of its width, wherein the first and second scores or creases together define a foldable panel in the vertical wall.

The one or more cutters may be movable with respect to the frame separately from or together with one or each of the marking devices. At least one or each of the marking devices may comprise a cutter, which may be movable between a retracted position, e.g. in which it is at least partially concealed, and/or a deployed position, e.g. in which a cutting edge thereof is exposed. The controller may be configured to position at least one or each of the marking devices by moving it along the vertical edge, for example such that the cutter cuts the vertical edge as the marking device is moved therealong.

A further aspect of the invention provides a method of forming a container or carton, for example using a device as described above.

Another aspect of the invention provides method of forming a container or carton, the method comprising determining, e.g. automatically, the height of one or more objects contained within an open top carton, positioning, e.g. automatically, a marking device based on the determined height and scoring or creasing, e.g. automatically and/or simultaneously, adjoining first and second vertical walls of the carton, e.g. to define at least part of a foldable panel in each of the first and second walls.

The method may comprise positioning, e.g. automatically, a first marking device based on the determined height. The method may comprise forming or causing to be formed, e.g. automatically, a first score or crease, e.g. from a first vertical edge of a vertical wall of the carton and/or across a first part of the width of the wall, using the first marking device. The method may comprise positioning, e.g. automatically, a second of the marking devices based on the determined height. The method may comprise forming or causing to be formed, e.g. automatically, a second score or crease, e.g. from a second vertical edge of the wall and/or across a second part of its width, using the second marking device, for example such that the first and second scores or creases together define a foldable panel in the vertical wall.

A yet further aspect of the invention provides a method of forming a container or carton, the method comprising determining, e.g. automatically, the height of one or more objects contained within an open top carton, positioning, e.g. automatically, a first marking device based on the determined height, forming or causing to be formed, e.g. automatically, a first score or crease from a first vertical edge of a vertical wall of the carton across a first part of the width of the wall using the first marking device, positioning, e.g. automatically, a second of the marking devices based on the determined height and forming or causing to be formed, e.g. automatically, a second score or crease from a second vertical edge of the wall across a second part of its width using the second marking device, for example such that the first and second scores or creases together define a foldable panel in the vertical wall.

The method is preferably carried out using a controller. The method may comprise scoring or creasing adjoining first and second vertical walls of the carton using the first marking device. The method may also comprise scoring or creasing adjoining second and third vertical walls of the carton using the second marking device, for example such that a foldable panel is defined in the second wall of the carton in part by each of the scores or creases formed by each of the first and second marking devices.

Yet another aspect of the invention provides a method of forming a container or carton, the method comprising determining, e.g. automatically, the height of one or more objects contained within an open top carton, positioning, e.g. automatically, a first marking device based on the determined height, scoring or creasing or causing to be scored or creased, e.g. automatically, adjoining first and second vertical walls of the carton using the first marking device and positioning, e.g. automatically, a second marking device based on the determined height and scoring or creasing or causing to be scored or creased, e.g. automatically, adjoining second and third vertical walls of the carton using the second marking device, for example such that a foldable panel is defined in the second wall of the carton in part by each of the scores or creases formed by each of the first and second marking devices.

The method may comprise positioning, e.g. automatically, a third and/or a fourth and/or subsequent marking device based on the determined height. The method may comprise scoring or creasing or causing to be scored or creased, e.g. automatically, adjoining third and fourth vertical walls, for example using the third marking device, e.g. such that a foldable panel is defined in the third wall of the carton in part by each of the scores or creases formed by each of the second and third marking devices. The method may comprise scoring or creasing or causing to be scored or creased, e.g. automatically, adjoining first and fourth vertical walls, e.g. using the fourth marking device, for example such that a foldable panel is defined in the first wall of the carton in part by each of the scores or creases formed by each of the first and fourth marking devices and/or such that a foldable panel is defined in the fourth wall of the carton in part by each of the scores or creases formed by each of the third and fourth marking devices.

The first and second vertical walls may be scored or creased substantially simultaneously and/or the second and third vertical walls may be scored or creased substantially simultaneously and/or the third and fourth vertical walls may be scored or creased substantially simultaneously and/or the first and fourth vertical walls may be scored or creased substantially simultaneously. In some embodiments, all of the first, second, third and fourth walls may be scored or creased substantially simultaneously. The first and third marking devices may be positioned substantially simultaneously and/or the second and fourth marking devices may be positioned substantially simultaneously.

The method may comprise forming or causing to be formed, e.g. automatically, a first score or crease from a first vertical edge of each vertical wall of the carton across a first part of the width of the wall using the first and third marking devices. The method may further comprise forming or causing to be formed, e.g. automatically, a second score or crease from a second vertical edge of each vertical wall of the carton across a second part of the width of the wall using the second and fourth marking devices. The forming or causing to be formed of the first and second scores or creases may be such that a foldable panel is defined in each wall in part by each of the first and second scores or creases.

In some embodiments, the method comprises forming cartons having a footprint comprising a polygonal shape having more or less than four sides. In such embodiments, the method may comprise the use of more or less than four marking devices in a manner that will be appreciated by the skilled person from the disclosure herein.

The method may comprise folding one or more or each of the foldable panels formed, for example automatically and/or using a folding device. The method may further comprise closing the carton, for example automatically and/or using a carton closing device that may be operable or configured to secure two or more foldable panels together. The method may comprise determining, e.g. automatically, the footprint of an open top container or carton, for example using the measuring means. The method may further comprise determining, e.g. automatically, the position of the vertical edges of the container or carton, for example based on the determined footprint and/or using a controller. The method may further comprise determining, e.g. automatically, the required height of the container or carton, for example based on the determined height of the one or more objects, e.g. using the controller. The method may further comprise positioning or causing the controller to position the one or more cutters, e.g. to a position adjacent each of the vertical edges. The method may comprise cutting or causing the controller to cut each of the vertical edges between an upper edge of the container or carton and a position at or adjacent the required container or carton height. The method may comprise positioning or causing the controller to position the one or more markers to a position adjacent each of the vertical walls and/or to score or crease each of the vertical walls between the vertical edges, e.g. at a position at or adjacent the required container or carton height, for example such that one or more foldable flaps or panels are defined in the vertical walls, e.g. between the score or crease lines and/or the cut vertical edges and/or the upper edge of the container or carton.

The method according to this aspect of the invention may comprise one or more steps relating to the implementation of any of the features of configuration of the device according to the first aspect of the invention.

For the avoidance of doubt, any of the features described herein apply equally to any aspect of the invention. For example, the system or apparatus may comprise any one or more features of the marking device and/or the method may comprise any one or more features or steps relevant to or relating to the implementation of any one or more features of the system or apparatus or the marking device.

Another aspect of the invention provides a computer program element comprising and/or describing and/or defining a three-dimensional design for use with a three-dimensional printing means or printer or additive manufacturing means or device, the three- dimensional design comprising an embodiment of one or more features of the system or apparatus or marking device, e.g. one or both of the forming tools, described above. A further aspect of the invention provides a computer program element comprising computer readable program code means for causing a processor to execute a procedure to implement the aforementioned method. A yet further aspect of the invention provides the computer program element embodied on a computer readable medium.

A yet further aspect of the invention provides a computer readable medium having a program stored thereon, where the program is arranged to make a computer execute a procedure to implement the aforementioned method.

A yet further aspect of the invention provides a control means or control system or controller comprising the aforementioned computer program element or computer readable medium.

For the avoidance of doubt, the term 'vertical' as used herein is intended to mean extending generally vertically rather than a specific orientation. Similarly, the term 'controller' is intended to mean any suitable control system including, but not limited to, a single unit with a single or multiple processors, multiple units with one or more processors that need not be physically connected together.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. For the avoidance of doubt, the terms "may", "and/or", "e.g.", "for example" and any similar term as used herein should be interpreted as non-limiting such that any feature so-described need not be present. Indeed, any combination of optional features is expressly envisaged without departing from the scope of the invention, whether or not these are expressly claimed. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which: Figure 1 is a perspective view of a carton sizing system according to an embodiment of the invention;

Figure 2 is an enlarged perspective view of part of the first creasing station of the system of Figure 1 in use;

Figure 3 is a perspective view of the creasing assembly of Figure 2;

Figure 4 is an enlarged perspective view of one of the pairs of forming tools of the creasing assembly of Figure 3;

Figure 5 is a perspective view of the creasing assembly of the second creasing station of the system of Figure 1 ;

Figure 6 is an enlarged perspective view of part of the folding station of the system of Figure 1 in use;

Figure 7 is a perspective view of the folding assembly of Figure 6;

Figure 8 is an enlarged perspective view of part of the folding assembly of Figure 7 showing the suction device; and

Figure 9 is a perspective view of the carton closing station of the system of Figure 1.

Referring now to Figure 1 , there is shown a carton sizing system 1 according to an embodiment of the invention, including a longitudinal frame 2, a conveyor 3 and a pair of control units 40, 41 referred to collectively herein as the controller 4. The system 1 also includes a measuring device 42 in the form of a vision system mounted to and operatively connected to the first control unit 40, a first marking station 5, a second marking station 6, a folding station 7, a closing station 8 and an inspection device 9 also in the form of a vision system mounted to and operatively connected to the second control unit 41.

The frame 2 includes a longitudinal dimension L, a transverse dimension T, an infeed end 21 , a discharge end 22 and a pair of gantry rails 23 mounted to an upper portion of the frame 2 and extending along the longitudinal dimension L. The first creasing station 5, second creasing station 6 and folding station 7 are all mounted to the gantry rails 23.

The conveyor 3 extends through the frame 2 along the longitudinal dimension L and includes an infeed conveyor segment 30, a sizing conveyor segment 31 , a closing conveyor segment 32 and a discharge conveyor segment 33. The infeed conveyor segment 30 includes a plurality of rollers 30a driven by an electric motor (not shown). The sizing conveyor segment 31 includes an electric motor 34 that drives an endless chain loop incorporating a series of spaced stop elements 35 configured to push the base of a carton C along a pair of support rails 36. The closing conveyor segment 32 includes an endless drive belt 37 extending between a pair of rollers (not shown) one of which is driven by an electric motor (not shown). Each of the electric motors 34 of the conveyor segments 30, 31 , 32 is also operatively connected to and controlled by the controller 4. The discharge conveyor segment 33 is inclined downwardly from the closing conveyor segment 32 and includes a plurality of rollers 33a that are free to rotate independently to enable cartons C to be conveyed therealong by gravity.

The first control unit 40 is mounted to the infeed end 21 of the frame 2, such that one end of the infeed conveyor segment 30 is disposed beneath the measuring device 42. The second control unit 41 is mounted to the discharge end 21 of the frame 2, such that one end of the discharge conveyor segment 33 is disposed beneath the inspection device 9. The measuring device 42 and the inspection device 9 each include an image capture device (not shown). The measuring device 42 is operable to determine the footprint of, and the height of the goods contained in, each carton C passing thereunder. The inspection device 9 is configured to verify the closure of a carton C passing thereunder.

Referring now to Figure 2, the first marking station 5 includes two forming devices 50, 51 each having a pair of opposed forming tools 52, 53 connected to a first end of a respective arm 52a, 53a pivotally connected together intermediate their ends such that the tools 52, 53 receive, in use, a portion of two adjoining walls of a carton C therebetween.

As shown more clearly in Figure 3, the first marking station 5 also includes a support plate 54 to which each forming device 50, 51 is movably mounted via a respective carriage plate 54a. One of the forming devices 50 is mounted adjacent a first corner of the support plate 54 and shall be referred to herein as the first forming device 50, whilst the other of the forming devices 51 is mounted adjacent a third corner of the support plate 54 opposite the first corner and shall therefore be referred to herein as the third forming device 51.

Each carriage plate 54a is mounted to the support plate 54 via an intermediate plate 54d and is movable along the transverse dimension T of the frame 2 on a pair of rails 54b on the intermediate plate 54d by a ball screw drive assembly 54c. The intermediate plate 54d of the third forming device 51 is movable along the longitudinal dimension L of the frame 2 on a pair of rails 54e mounted to the support plate 54 by a further ball screw drive assembly 54f.

Each forming device 50, 51 is mounted to its respective carriage plate 54a via a vertically oriented ball screw drive assembly 55 connected at its free end to the arms 52a, 52b and operable to move the arms 52a, 53a and forming tools 52, 53 vertically. Each of the vertical drive assemblies 55 extends through a respective aperture in the support plate 54, while the vertical drive assembly 55 of the third forming device 51 also extends through an aperture in the intermediate plate 54d.

The first forming device 50 is therefore movable vertically and in the transverse dimension T, while the third forming device 51 is movable vertically and along both the transverse and longitudinal dimensions T, L.

Each forming device 50, 51 also includes a pneumatic creasing actuator 56 connecting a second end of each arm 52a, 53a, opposite the first end that carries the forming tool 52, 53. The pivot between the arms 52a, 53a is closer to the second end than to the first end, thereby enabling the use of compact creasing actuators 56 by amplifying the separation of the forming tools 52, 53 relative to the movement of the creasing actuator 56. This provides several advantages that would be appreciated by the skilled person.

As shown more clearly in Figure 4, the outermost forming tool 52 of each forming device 50, 51 includes a flat plate 52b having a substantially V-shape in plan with a pair of inner flanks 52c extending orthogonally relative to one another and defining vertical forming surfaces 52c, which are perpendicular with respect to the major surfaces of the plate 52b. The plate 52b also includes a recess 52d at the join between the forming surfaces 52c for receiving the corner of a carton C therein such that outer surfaces of adjoining walls of the carton C rest against the forming surfaces 52c. The outermost forming tool 52 also includes a pair of wedge shaped lead-in members 52e mounted to the plate 52b which are angled outwardly from the bottom of the vertical forming surfaces 52c, thereby to provide lead-in surfaces in the event of a slight misalignment between the forming tool 52 and the adjoining walls of the carton C.

The innermost forming tool 53 of each forming device 50, 51 includes a flat plate 53b having a substantially triangular shape in plan with a pair of outer flanks 53c defining blade-shaped forming edges 53c for bearing against the forming surfaces 52c of the outermost forming tool 52. Each of the forming edges 53c of the innermost forming tool 53 is configured to bear against a respective one of the forming surfaces 52c of the outermost forming tool 52 when the tools 52, 53 are brought together. As will be understood from Figure 2, creases may be formed simultaneously in a pair of adjoining walls of a carton C when each is captivated between one of the forming surfaces 52c and one of the forming edges 53c as the tools 52, 53 are brought together.

The innermost forming tool 53 also includes a cutter 53d with a cutting blade having a cutting edge that extends upwardly and outwardly from the join between forming edges 53c. The blade of the cutter 53d is substantially aligned with the recess 52d when the tools 52, 53 are brought together. In some embodiments, the cutter 53d includes a deployable cutting blade, which is movable between retracted and deployed positions, but in this embodiment the blade remains in the deployed position. Thus, when the tools 52, 53 are brought to an intermediate position, with a small gap between the forming surfaces 52c and the forming edges 53c, downward movement of the forming tools 52, 53 causes the cutter 53d to cut and split the vertical corner edge of the carton C captivated therebetween.

Referring now to Figure 5, the second marking station 6 is shown, which is similar to the first marking station, wherein like references depict like features and will therefore not be described further herein. The support plate 54 is omitted from Figure 5 for clarity, but the second marking station 6 includes a pair of forming devices 60, 61 each of which is mounted to a respective one of second and fourth corners of the support plate (not shown) of the second marking station 6 and shall therefore be referred to herein respectively as second and fourth forming devices 60, 61. Each forming device 60, 61 of the second marking station 6 is movably mounted to the support plate (not shown) via respective carriage plates 54a. The carriage plate 54a of the second forming device 60 is securely mounted to the support plate (not shown) in a similar manner to the first forming device 50 described above and the intermediate plate 54d of the carriage plate 54a of the fourth forming device 61 is mounted to the support plate (not shown) in a similar manner to the third forming device 51 described above. Specifically, each carriage plate 54a is movable along the transverse dimension T of the frame 2 on a pair of rails 54b by a ball screw drive assembly 54c. The intermediate plate 54d of the carriage plate 54a to which is mounted the fourth forming device 61 is movable along the longitudinal dimension L of the frame 2 on a pair of rails 54e mounted to the support plate (not shown) by a further ball screw drive assembly 54f.

Accordingly, each of the first, second, third and fourth forming devices 50, 51 , 60, 61 is configured to receive a respective first, second, third and fourth corner of a carton C to be formed. The aforementioned arrangement provides infinite Cartesian adjustment of the position of the forming devices 50, 51 , 60, 61 , thereby enabling cartons C of any size within the operating envelope of the system 1 to be accommodated. It will be appreciated by the skilled person that the minimum carton width and length are dictated by the lengths of the opposed forming surfaces 52c and forming edges 53c, while the maximum width and length corresponds to double the said length. In some embodiments, however, cartons C having a greater length or width than this may be formed with an interrupted crease, provided that the uncreased portion does not inhibit the folding of a panel defined by the cut corners and the interrupted creases.

Referring now to Figures 6 to 8, the folding station 7 includes a pair of support rails 70 mounted to the gantry rails 23 of the frame 2, such that they extend along the transverse dimension T, and a support plate 71 spanning the support rails 70 to which a vertical ball screw drive assembly 73 is mounted. The vertical drive assembly 73 is operable to raise and lower a subframe 74 that includes a vertical arm 74a carrying a pair of orthogonal rail members 74b, 74c each of which carries a pair of opposed folding arms 75a, 75b. A first rail member 74b extends along the longitudinal dimension L and movably carries a first pair of opposed folding arms 75a extending along the transverse dimension, while a second rail member 74c extends along the transverse dimension T and movably carries a second pair of opposed folding arms 75b on each transverse side and extending along the longitudinal dimension L. Each rail member 74b, 74c includes a ball screw drive assembly 76 for moving the folding arms 75a, 75b thereof apart from or toward one another. Thus, each folding arm 75a, 75b is infinitely adjustable to accommodate cartons C of any size within a predetermined operating envelope.

Each of the first folding arms 75a includes a pneumatic folding actuator 77 connected at its free end to the centre of an elongate folding finger 77a extending horizontally and orthogonal to the actuator 77. The folding finger 77a is guided by a pair of guide rods 77b each connected thereto adjacent one of its ends and slidably received in a respective aperture in a guide plate 77c fixed to the folding arm 75a. Each of the second folding arms 75b includes a pneumatic folding actuator 78 similar to the folding actuator 77 of the first folding arms 75a, but wherein the folding finger 77a is replaced with a folding roller 78a. Each of the second folding arms 75b also includes a suction device 79 above the folding roller 78a for selectively retaining a flap defined in a respective one of the side walls of a carton C to be formed while the flaps defined in the end walls are folded by the folding fingers 77a of the first folding arms 75a.

Referring now to Figure 9, the closing station 8 includes a top conveyor 80 with a pair of spaced endless belts extending between rollers (not shown), one of which rollers is movable by an electric motor 81. The closing station 8 also includes a tape applicator 82 mounted to the top at the centre of the top conveyor 80 for applying tape between the belts to a carton C passing thereunder, thereby to retain the flaps of the carton C in a closed condition. The top conveyor 80 is mounted to and movable vertically along a pair of vertical rails 83, one of which is located on either side of the closing conveyor segment 32.

In use, a partially filled carton C is placed onto the infeed conveyor segment 30, where it is conveyed to the infeed end 21 of the frame 2 onto the sizing conveyor segment 31. The measuring device 42 determines the footprint of, and the height of the goods contained in, the carton C as it passes thereunder and the controller 4 adjusts the position of each of the forming devices 50, 51 , 60, 61 and the folding arms 75a, 75b according to the measured footprint of the carton C. The carton C then enters the first marking station 5 and the first and third forming devices 50, 51 are lowered to a vertical position slightly higher than the measured height of the goods in the carton C. As the first and third forming devices 50, 51 are lowered, the cutters 53d cut the first and third corner vertical edges of the carton C and, subsequently, the tools 52, 53 are brought together such that the forming surfaces 52c and forming edges 53c form creases in each of the four walls adjacent the first and third corners simultaneously. The tools 52, 53 are then separated and the first and third forming devices 50, 51 are then raised clear of the carton C.

The sizing conveyor segment 31 then moves the carton C to the second marking station 6, wherein the second and fourth forming devices 60, 61 are lowered to a similar vertical position as the first and third forming devices 50, 51. As the second and fourth forming devices 60, 61 are lowered, the cutters 53d cut the second and fourth corner vertical edges of the carton C. The tools 52, 53 of the second and fourth forming devices 60, 61 are brought together such that the forming surfaces 52c and forming edges 53c form creases in each of the four walls adjacent the second and fourth corners simultaneously, a portion of which will normally overlap part of the crease formed by the first and third forming devices 50, 51. The tools 52, 53 are then separated and the second and fourth forming devices 60, 61 are then raised clear of the carton C.

The sizing conveyor segment 31 then moves the carton C to the folding station 7 and the folding arms 75a, 75b are lowered to a position in which the folding fingers 77a and folding rollers 78a are slightly higher than the creases formed in the carton C. The suction device 79 of the second folding arms 75b is then activated to retain the hinged panels defined by the creases in the side walls of a carton C while the hinged panels defined by the creases in the end walls are folded by the folding fingers 77a of the first folding arms 75a. With the folding fingers 77a deployed, the suction device is disabled and the rollers 78a are deployed to force the hinged panels defined by the creases in the side walls of a carton C. Before the rollers 78a reach their fully deployed position, the folding fingers 77a are retracted and the side wall hinged panels are forced to a fully closed position.

The sizing conveyor segment 31 then moves the carton C onto the closing conveyor segment 32 and into the closing station 8, where the tape applicator 82 applies tape between the belts of the top conveyor 80 to the carton C as it passes thereunder, thereby to retain the flaps of the carton C in a closed condition. The carton C is conveyed by the closing conveyor segment 32 to the discharge conveyor segment 33 and under the inspection device 9 to verify the closure of a carton C after which it is conveyed along the discharge conveyor segment 33. If the inspection device 9 detects an issue, an alarm is generated to alert an operator to visually inspect the closed carton C. It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention. For example, at least one or each of the motors may be, for example, electric, electromagnetic, hydraulic or pneumatic motors. Additionally or alternatively at least one or each of the motors may be driven electrically or electromechanically or electromagnetically or hydraulically or pneumatically. The sealing device 84 need not utilize tape to seal the carton closed but may, for example, apply adhesive or shrink wrap or any other material suitable for sealing the carton closed.

In this embodiment, four forming devices 50, 51 , 60, 61 are provided each having forming surfaces 52c and forming edges 53c defining a right angle so as to accommodate cartons having a square footprint. However, it will be understood by the skilled person that more or less forming device 50, 51 , 60, 61 may be provided with forming surfaces 52c and forming edges 53c defining an acute or obtuse angle as required to accommodate cartons having non-square footprints. Similarly, the forming surfaces 52c and forming edges 53c need not be as described, they may be interrupted and sharp, for example, so as to cut into the carton and define a fold line or a frangible line. Other arrangements may also be useful.

It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.