The present invention relates to an improved industrial plant and method, in particular to a module, or apparatus, and a method of in-line packing of objects. Such objects are components for furniture (e.g. base, wall or column units).

It is known that to protect furniture or furniture items, taken here as an example, during transport they are stuffed into a custom-made cardboard box. In addition to the inconvenience of producing or having in stock many boxes, bulky and expensive, for each size of furniture, there is that of having to physically box the furniture items, an operation that requires a lot of human labor and space to be performed.

It is easily understood that such a system has several disadvantages, such as low productivity and high operating cost.

The main object of the invention is to improve the present state of the art. Another object is to make an improved industrial method and plant for packing an object (e.g. a furniture item), or a part thereof, that uses less protective material, e.g. less cardboard, and is faster.

These and other objects are achieved by what is stated in the attached claims; advantageous preferred technical solutions are defined in the dependent claims.

An aspect of the invention is a method for packing an object, comprising the step of applying around the object a plurality of bands of protective material at a different vertical height of the object, wherein the bands are applied so that they are spaced apart and distributed along the height of the object (preferably so that there are not two bands at the same height).

Another aspect of the invention concerns a plant for packing an object, comprising:

N packing stations arranged in series, N >= 2, wherein each N-th station comprises an applicator device to apply around the object one or more bands of protective material at a different vertical height of the object, wherein the bands are applied so that they are spaced apart and distributed along the height of the object (preferably without mutual overlapping, i.e. there are not two bands at the same height).

Known manipulators, drives, robots and conveyors too may be used in the apparatus and method.

An advantage of the method is that custom-made boxes or packaging are no longer needed while still providing sufficient protection for the object. With the aforementioned bands, effective protection of the object's edges (the areas most exposed to impact) is achieved without covering its entire surface, saving on protective material. Another advantage is the possibility of having in stock a single protective material that serves to protect all the variable shapes or volumes of the object.

Below are shared variants for the method and the plant. The stations of the plant may perform any or all steps defined here for the method.

In a variant, the bands are applied to the object at the same time.

In a different variant, which improves cycle time by avoiding stopping the object at the same point for a long time, the bands are applied to the object sequentially, one after the other and/or one at a time. That is, an additional band is applied only when the application of the current band is finished. The bands are applied on the same object sequentially and progressively, and at consecutive stations or points of a packing line. At each point or station only one band or several bands are applied at different heights of the object, and when the object has sequentially visited all points or stations it will have received all bands. The bands applied by an N-th station are placed on the object at heights different from each other, and at heights different from those of the bands applied by the other (N-1 ) stations.

Preferably, the application of each individual band is performed in-line by a distinct machine. Such a machine is dedicated to the application of only one band. Where cycle time permits, only one machine may apply all the bands or several machines may each apply a subset of the total bands. That is, one machine can apply a subset of the total bands.

In a preferred variant, the method comprises the steps of sequentially advance the object through N stations, N >= 2, and each N-th station applies around the object one or more bands, in particular only one band, of protective material on the object at a height different for each band.

Preferably the bands are applied to the object so that they are spaced apart and evenly distributed along the height of the object.

More preferably, the position of a or each band to be applied to the object is calculated by measuring a physical variable of the object (in particular a dimensional variable), e.g. its height and/or weight and/or width and/or color and/or the material making it up.

Even more preferably, the distance between two adjacent bands is a function of the total height of the object. For instance, called H the height of the object and having a total of N bands applied to the object, the distance between two adjacent bands is H/N. This criterion is met for the bands applied by each station and for the set of bands applied by all stations overall.

Preferably, each band is applied on the object at a height that is a function (e.g. a fraction) of the total height of the object. E.g., if the total N bands are evenly spaced, to optimize the spacing of the bands each N-th band is preferably applied on the object at a height (relative to the base of the object) equal to J*H/N, or (J-1 )*H/N, or (J-1/2)*H/N, respectively, with J = 1 , 2, ..., N.

To have omnidirectional protection, preferably a band of protective material is attached at its ends (e.g. glued or stapled) to form a ring around the object.

For convenience, the protective material is preferably a cardboard ring or band.

Preferably, to increase protection, a plastic film or cardboard sheet is applied to the object, more preferably on top of the object to cover its top. E.g. the plastic film or cardboard sheet is applied to the object at a dedicated station, e.g. placed at the beginning or end of the series of N stations.

In particular, the plastic or cardboard cover film may be applied at the entry point of the row of stations, case in which preferably it is folded following the shape of the object and is blocked by the top band that will be placed first. Or the plastic or cardboard cover film may be applied at the exit from the row of stations, case in which preferably it is folded following the shape of the object and glued on the top band.

Preferably the object is a set of distinct things superimposed and stacked vertically on top of each other, and/or a furniture item, or in particular a set of furniture items or furniture components superimposed and/or stacked vertically.

Preferably, the object is laid on a pallet while it receives the bands, so that after packing it can be shipped easily and ready for travel.

In a variant, each of the N stations is configured to apply on the object only one band at a different height of the object, or to apply on the object a subset of the total bands where each band of the subset is at a different height of the object.

In a preferred variant, the plant comprises a conveyor device to sequentially advance the object through the N stations.

In a variant, each of the N stations is configured to apply one or more bands to the object so that they are spaced apart and evenly distributed along the height of the object, and more preferably, the distance between two adjacent bands is a function of the total height of the object, e.g. as defined above for the method.

In a variant, each of the N stations comprises means or a device for closing a band at the ends thereof (e.g. to glue or staple it) so as to form a ring around the object.

Preferably, the plant comprises a station configured to apply a plastic film or cardboard sheet to the object, more preferably at the top of the object.

Preferably, the plant comprises said N stations arranged in series (in tandem fashion) and fed by a conveyor belt configured to sequentially carry an object from one station to the next along a feed axis.

Preferably, each station comprises two reels of protective material feeding an applicator device, which preferably comprises a first pair of arms and a second pair of arms, wherein the arms of each pair are aligned, placed opposite each other on opposite sides of the conveyor belt, and linearly movable along a respective axis which is horizontal and orthogonal to a vertical plane passing through the feed axis.

Preferably, a roller is mounted at the end of each arm of the first pair to return a band of protective material around the object.

Preferably, the arms of the first pair are movable, relatively displaceable closer to or away from each other, to widen or narrow a horizontal stretch of protective material stretched between their ends so that the object encounters the stretch frontally.

Preferably, the arms of the second pair are movable, relatively displaceable closer to or away from each other, to bring two bends of protective material closer behind the object.

Preferably, the plant comprises a gluing head provided with means for cutting the protective material, applying glue to the ends of the cut strip, and then pressing said ends on top of each other to close the strip and make a ring.

Preferably, said pairs of arms are linearly and synchronously movable along a vertical axis (Fig. 3), orthogonally to a horizontal sliding surface of the conveyor belt, to apply to the object bands at different heights.

Preferably, the two pairs of arms are linearly and synchronously movable along an axis parallel to the feed axis.

Preferably the plant comprises:

- an electronic control unit, - a code reader connected to the control unit and/or a sensor (e.g. an image sensor, a camera, or a LIDAR) connected to the control unit to detect the shape of the object.

The control unit is configured to

- receive the code, or data, from the reader or sensor,

- extract information about the total height of the object,

- establish a program of how many bands and at what height each station has to apply, and

- send commands to a drive of the stations to carry out the program.

Preferably, the plant comprises a distributor for applying a protective sheet over the object. In particular, the distributor is placed at the entry or exit point of the conveyor belt and comprises a portal that supports a reel at the top thereof from which the sheet is unrolled. In particular, the portal has two lateral columns and an upper crossbar, wherein the upper crossbar is adjustable in height by a drive.

Further advantages will become clear from the following description, which refers to an example of a preferred embodiment of a packaging machine in which:

Fig. 1 shows a plan view of a packaging plant or machine,

Fig. 2 shows a plan view of a module or stations of the packaging plant or machine,

Fig. 3 shows in side view a series of objects during packing.

Equal numbers in the figures indicate equal or substantially equal parts.

A packing machine 10 (fig. 1) comprises the in-line series of three equal stations or modules 12, 14, 16 fed by a conveyor belt 20 configured so that an object 18, placed on it, can reach and pass sequentially through the modules 12, 14, 16 moving along a horizontal feed X axis (see also arrow F). The modules 12, 14, 16 may also be just one, two, or more than three.

Preferably the object 18 travels on a pallet 19.

Each module 12, 14, 16 (see detail of Fig. 2) is configured to apply a band of protective material, e.g. cardboard, around the object 18. For this purpose, each module 12, 14, 16 comprises two reels 30, 32 of protective material 28 that feed an applicator device 34. The use of two reels 30, 32 allows a module 12, 14, 16 to remain active during the replacement of an empty reel.

The applicator device 34 is structured to lay a strip of protective material 28 in front of the object 18 and then fold the strip around the object 18 as the object 18 advances on the conveyor belt 20. Specifically, the applicator device 34 comprises a pair of arms 40 and a pair of arms 50. The arms 40, 50 of each pair are aligned, placed opposite each other on opposite sides of the conveyor belt 20, and linearly movable along a respective axis Y1 , Y2 that is horizontal and orthogonal to a vertical plane passing through the X axis.

As the object 18 moves along the X axis, the pair of arms 50 is reached by the object 18 first, the pair of arms 40 secondly.

A roller 42 is mounted at the end of each arm 40 to return the strip of protective material 28 around the object 18.

The arms 40 are movable, relatively displaceable closer to or away from each other, to widen or narrow a horizontal stretch 44 of protective material 28 that the object 18 encounters frontally. Thus the arms 40 adjust the transverse length of the horizontal stretch 44 to the width of the object 18. Then the object 18, moving on the conveyor belt 20, drags the horizontal stretch 44 and lays it on its sides.

The arms 50 are movable, relatively displaceable closer to or away from each other, to bring two bends of protective material 28 closer to each other behind the object 18 and thus form a segment of band that can be closed behind the object 18.

To close the band around the object 18, each module 12, 14, 16 comprises e.g. a gluing head 36 with means for cutting the protective material 28, applying glue to the ends of the cut strip and then pressing them on each other to close the strip and make a ring. E.g. the gluing head 36 is mounted at the end of one or each arm 50.

The pair of arms 40 and the pair of arms 50 are also linearly and synchronously movable along a vertical Z-axis (Fig. 3), i.e. orthogonally to the horizontal sliding surface of the conveyor belt 20. Therefore, the arms 40, 50 are movable to be vertically displaced closer to or away from the conveyor belt 20. Therefore, by moving the arms 40, 50 along the Z axis it is possible to vary the elevation of the segment 44 relative to the conveyor belt 20, thereby varying the height to which the band of protective material 28 currently applied on the object 18, is applied.

The pair of arms 40 and the pair of arms 50 are preferably also linearly and synchronously movable along an axis parallel to the X axis. Thus they can position themselves along the conveyor belt 20 to track the object 18 when necessary.

The modules 12, 14, 16 are configured to work independently, then each module 12, 14, 16 can apply a strip or rings 96 of protective material 28 to the object 18 at a height different than that engaged by the other modules 12, 14, 16. See e.g. Fig. 3 showing an example of progressive packing on the machine 10. As the object 18 advances on the conveyor belt 20 it receives at least one band of protective material 28 from each module 12, 14, 16, so that, at the exit point of the machine 10, around the object 18 there is a plurality of bands or rings 96 of protective material 28 that are spaced apart and distributed along the height of the object 18 without mutual overlapping.

For maximum machine-cycle speed, each module 12, 14, 16 applies only one band of protective material 28. However, it is possible to equip a or each module 12, 14, 16 with more pairs of arms 40, 50 to apply simultaneously to the object 18 several bands at different heights.

For example, relatively to the conveyor belt 20, the band 96 applied at highest level is at 2500 mm, and the 96 band applied at lowest level is at 350 mm.

The height to which each module 12, 14, 16 applies its band 28 of protective material may be constant, or determined in real time by a program and/or an electronic control unit 60, e.g. a PC or PLC. The control unit 60 drives all the actuators of the modules 12, 14, 16, including those that set the position of the arms 40, 50.

In a variant, the object 18 has a code that is read by a reader 62, placed at the entry point of the conveyor belt 20 and connected to the control unit 60. In a different variant, the object 18 is recognized by a sensor 64 (e.g. an image sensor, a camera, or a LIDAR) placed at the entry point of the conveyor belt 20 and connected to the control unit 60.

The control unit 60 receives the code, or data, from the reader 62 or the sensor 64 and extracts information therefrom regarding the total height of the object 18. By means of an algorithm then the control unit 60 determines how many bands and at what height each module 12, 14, 16 has to apply, and gives them commands accordingly.

To increase the protection of the object 18, the machine 10 optionally comprises a dispenser 70, e.g. also of known type, to lay a protective sheet 72 on the object 18. E.g. the sheet 72 is a plastic film, e.g. a polyethylene sheet, which is dustproof and waterproof. E.g. the sheet 72 is applied to the top of the object 18 to cover it from dust.

The dispenser 70 is placed at the entry or exit point of the conveyor belt 20, for construction convenience, and comprises a portal 74 that supports a reel 76 at the top from which the sheet 72 is unwound.

The portal 74 has two lateral columns 78 and an upper crossbeam 80. The upper crossbar 80 is adjustable in height by a drive 81. The distributor 70 comprises rollers, e.g. rubber-coated, for unwinding the sheet 72. The reel 76 is cut by means of a full-width blade: the distributor 70 has means on board for holding the sheet 72 from above and below while the blade cuts it.

Fig. 3 shows a typical snapshot situation for various objects 18 on the conveyor belt 20. The objects 18 are in a row along the X axis and some are formed of a stack or column of components. Along the overall height of the object 18, closed bands or rings 96 of protective material 28 are progressively applied by the modules 12, 14, 16.

Going from right to left: an object 18 arrives and a first band or ring 96 is applied to it at the module 12, then - if the height of the object 18 requires it - a second band or ring 96 is applied at the module 14, and then - if the height of the object 18 requires it - a third band or ring 96 5 is applied at the module 16.

If the distributor 70 is at the head of the conveyor belt 20, going from right to left in Fig. 3 the sheet 72 is applied first, and then sequentially the bands or rings 96 along the succession of the modules 12, 14, 16.