The present invention also relates to a method of packaging articles.

In the pulp-based packaging industry, objects/articles, for example bottles, are packaged according to a desired arrangement of the articles by packaging machines. The packaging machines use pre-printed carton blanks to form packages around articles to be packed.

It is appreciated in the art that a given packaging machine can usually only package a limited number of arrangements of articles. Furthermore, deviation from the limited number of arrangements is only possible to a limited degree and would typically require time consuming and expensive mechanical and/or software modifications to the given packaging machine. In fact, adaptation of a packaging machine to pack different types, or different combinations of types, of articles carried by the package blanks used by the packaging machine usually requires a time consuming approval process between a manufacturer of the articles and the producer and/or printer of the package blanks.

The present invention seeks to overcome or at least mitigate the problems of the prior art.

According to a first aspect of the present invention, there is provided a packaging apparatus for packaging articles, the apparatus comprising a first feeder arranged to feed a package blank to a first conveyor for transporting the package blank received from the first feeder to an article transfer apparatus, the article transfer apparatus being arranged to receive articles from a second conveyor for transporting articles to be packed and to place at least one article presented by the second conveyor in at least one respective selectable position; a robotic blank manipulator arranged to manipulate the package blank so as to substantially assemble the package blank for containing the positioned at least one article, thereby substantially packaging the at least one article ; a third

conveyor for transporting the packaged at least one article away from the robotic blank manipulator.

Preferably, the robotic blank manipulator comprises an arm portion having a first end and a second end, a hand portion being coupled to the first end and freely rotatable about the first end. More preferably, the hand portion comprises a suction cup for holding the package blank. Most preferably, the suction cup is translatable relative to the first end.

Preferably, the second end of the arm portion in coupled to an arm translator arrangement by a coupling. More preferably, the coupling comprises a first part and a second part respectively coupled to the second end, a separation between the first and second parts being selectable so as to controllably raise and lower the first end.

Preferably, the article transfer apparatus comprises a translatable electromagnet for taking at least one article presented by the second conveyor and placing the at least one article in the at least one respective selectable position.

According to a second aspect of the present invention, there is provided an article transfer apparatus comprising an electromagnet for taking at least one article received from a conveyor of articles to be packed, the electromagnet being translatable in at least two dimension so as to move the at least one article to at least one respective selectable position within a predetermined region.

Preferably, the electromagnet is translatable in three dimensions by a set of motors arranged to respectively control translation of the electromagnet in the three dimensions.

According to a third aspect of the present invention, there is provided a packaging apparatus for packaging articles, the apparatus comprising a robotic blank manipulator arranged to manipulate a package blank so as to substantially assemble the package blank for containing at least one article to be packaged.

According to a fourth aspect of the present invention, there is provided a method of packaging at least one article, the method comprising the steps of : conveying the at least one articles to an article transfer apparatus ; arranging the at least one article in at least one respective selectable position using the article transfer apparatus; conveying a package blank to the positioned at least one article; robotically manipulating the package blank using a robotic blank manipulator so as to substantially assemble the package blank for containing the positioned at least one article; and conveying the substantially packaged at least one article away from the robotic blank manipulator.

A fifth aspect of the invention provides a robotic blank manipulator arranged to manipulate the package blank so as to at least part-assemble the package blank for containing the positioned at least one article, thereby at least part-packaging the at least one article; a third conveyor for transporting the packaged at least one article away from the robotic blank manipulator.

It is thus possible to provide a packaging apparatus and method therefor that is capable of providing the user with flexibility of choice as to combinations of packed product types/shapes, the type of package used and arrangement of the articles within the package type selected. Advantageously, the assembly of the package can be achieved in real time.

Exemplary 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 schematic diagram of a packaging machine constituting an embodiment of the invention; FIGURES 2 and 3 are schematic diagrams of a robotic hand of the packaging machine shown in Figure 1;

FIGURE 4 is a schematic diagram of a robotic arm drive arrangement of the packaging machine of Figure 1; FIGURE 5 is a schematic diagram of an article transfer apparatus of the packaging machine of Figure 1; and FIGURES 6 to 8 illustrate the movement of the manipulator for forming a wraparound carton, an end loaded carton and a basket carrier respectively.

Throughout the following description, identical reference numerals will be used to identify like parts.

Referring to Figure 1, a packaging machine 100 comprises a hopper 102 for storing carton blanks and a feeder 104 for feeding the carton blanks from the hopper 102 to a carton blank conveyor 106. In this embodiment, a rotary feeder is used, as is well known in the art. The carton blank conveyor 106 is disposed adjacent an article transfer apparatus 108.

Articles are supplied to the apparatus and are conveyed by an article conveyer 110 to an article transfer apparatus 108. The article transfer apparatus 108 presents articles to the loading station for loading the articles into a carton.

The machine is capable of loading different types and sizes of articles so each article type (or size) is supplied from different article streams which each supply articles to the transfer apparatus or converge upstream of the machine. In those embodiments in which there is upstream convergence, a selector mechanism of known type is used to select the order of articles in any particular array.

Referring to Figure 5, there is shown one embodiment of the article transfer apparatus 108 having a nested guide frame arrangement comprising an outer guide frame 400 arranged to carry an inner guide frame 402 in directions X". Guide means 404 is coupled to the inner guide frame 402 for movement in directions Y"and is capable of

moving along the inner guide frame 402. A first drive motor 406, is operably coupled to the inner guide frame 402 by an arrangement of drive belts, for example a first drive belt 408 and a second drive belt 410. A second drive motor 412 is operably coupled to the inner guide frame by a third drive belt 414. The terminus 404 of the article conveyor 110 is disposed adjacent one end of the inner guide frame 402.

In one class of embodiments, the guide means 404 is provided by a platform or lug, which is recessed to receive one or more articles. Alternatively, an electromagnet is used to engage an article or plurality of articles in which case the article (s) should be placed on a plate formed from material, which is capable of being moved by magnetic attraction to the electromagnet.

Of course, other known article transfer means can be used without departing from the scope of invention. For example, it is envisaged that the article grouping mechanism of W099/14722 could be employed and adapted for use with the present invention.

Turning again to Figure 1, a robotic blank manipulator 116 is disposed above the article transfer apparatus 108. A first end support 118 is coupled to a second end support 120 by a first guide shaft arrangement 122 and a second guide shaft arrangement 124, the first and second guide shaft arrangements 122,124 being parallel with respect to each other. The construction of the first end support 118 is the same as the construction of the second end support 120 and so the first end support 118 will only be described with reference to Figure 3.

The first end support has a support frame, preferably having an upright portion 300 (Figure 4) from which a crossbar portion 302 extends. The first guide shaft arrangement 122 is rotatably coupled to the crossbar portion 302 at a first end thereof, the second end thereof being coupled to a corresponding crossbar portion 303 of the second end support 120. Suitable drive means is operably coupled to the first guide shaft arrangement 122 to cause it to rotate about the opposed supports 302 and 303 in direction W. In the illustrated embodiment, the drive means is provided by a drive motor 304 and belt arrangement 306 mounted in the support, although it is envisaged

that the motor, for example a servo motor, could be coupled directly to the guide shaft 122. Optionally a second guide shaft arrangement 124 is provided which also rotatably coupled to the crossbar portion 302 in like manner to the first guide shaft arrangement 122, so is not described in any further detail.

The first guide shaft arrangement 122 carries further drive means operably coupled to a first arm 126 (Figure 1) of the robotic blank manipulator 116.

The first arm 126 comprises a first coupling part 130 and a second coupling part 132.

The first coupling part 130 pivotally couples a first end of a first arm shaft 134 to the first guide shaft arrangement 122. The second coupling part 132 pivotally couples a second arm shaft 136 and a third arm shaft 138 to the first guide shaft arrangement 122.

Second ends of the first, second and third arm shafts 134,136, 138 are pivotally coupled to an end bracket 140.

The first coupling part 130 is moved independently of the second coupling part 132. In this embodiment, first coupling part 130 is driven by a first endless belt 131 (Figure 4) and the second coupling part 132 is driven by a second endless belt 133. Both the first and second endless belts 131,133 are driven independently by suitable drive means 308 for example a servo motor.

In one class of embodiments, a pair of linear servo motor mounted to a guide rail is used to drive each coupling part 130,132.

In operation, the coupling parts are moveable along the guide shaft arrangement in plane X, shown in Figure 1, to convey the blank and/or the articles along the packaging apparatus. As each coupling part 130,132 is independently moveable, the arm can be raised by increasing the spacing between coupling parts or lowered by moving the coupling parts closer together in plane Y.

In some embodiments, a second arm 128 is provided which is connected to the second guide shaft arrangement 124 by couplings. The construction of the second arm 128

(and associated hand portion) is the same as the first arm 126 and so, for conciseness, the construction of the second arm 128 (and associated hand portion) will not be repeated.

Referring to Figures 2 and 3, a hand portion 200 of the manipulator is coupled to the end bracket 140. The hand portion 200 comprises suitable drive means to impart movement in directions P and Q. Accordingly, the arms 126,128 are able to move in the X, Y and Z planes (Figure 1) and the hand portions 200 have six degrees of freedom.

In this embodiment, a rotation motor unit 202 is coupled to the end bracket 140 and a hand support frame 204. The hand support frame 204 carries a first package manipulating lug 208 which is moved to and fro in direction Y'. A second package manipulating lug 212 is also carried by the hand support frame 204 which is moveable in direction Y'. The first lug 208 is translatable towards and away from the centre of the hand support frame 204 by a first hand drive motor (not shown). Similarly, but independently, the second lug 212 is translatable towards and away from the centre of the hand support frame 204 by a second hand drive motor (not shown). Preferably, the first and second lugs 208,212 are also translatable towards and away from the end bracket 140 in direction X'.

There may further comprise first and second suction cups 206,210 secured to the hand portion and adapted to engage and manipulate part of the carton, described in more detail below.

The first and second lugs 208,212 are suitably shaped to facilitate urging of parts of a package blank without damaging the package blank.

The hand portion 200 also comprises a separate blank engagement device 214. In this embodiment, the blank engagement device comprises a suction cup 216, which is pivotally connected to the coupling 202 about pivot 218. The blank engagement device 214 is rotatable about the pivot 218 in direction Q and it is powered by drive means

217, for example a servo motor. It is envisaged that other types of panel engagement device, for example lugs or pincers can be employed without departing from the scope of the invention. In this embodiment, the panel engagement device 214 moves from a vertical position for picking the blank up from the blank in feed to a horizontal position where it is folded around the articles.

The panel engaging device 214 is adapted to move along the guide rail 204 separately from the blank so that the engagement position with the blank can be adjusted according to the particular blank to be packaged.

Referring back to Figure 1, fixed guides 142 are disposed adjacent and downstream of the robotic blank manipulator 116 carton securing station 144 is disposed adjacent and downstream of the fixed guides 142. An out-feed conveyor 146 is disposed adjacent the carton securing station 144.

The packaging machine further comprises leading and trailing lugs 113,115, which are independently moveable towards or away from each other. Each lug is mounted to an endless belt 114 powered by separate drive means 112, for example a pair of servo motors. The leading and trailing lugs 113,115 are used to move some types of carton forward through the machine. Accordingly, each lug is moveable transversely in the machine between positions of use and inoperative positions so that just one or both of the lugs can be used individually, according to the particular requirements of the machine.

A controller is used to control the position and movement of the manipulator 116. In addition, the controller may also control the article transfer apparatus to select the chosen array of articles and to move them to position and the blank feeder to control the supply of blanks. The positions and velocity vectors of the drive motors for the various sub-assemblies of this apparatus can be input manually or a specific pre-written programme can be loaded into the central processor for control of the packaging machine. Also, for the controlled change over of the machine from one carton type or size to another can be the result of a pre-written program or a manual input signal.

In this embodiment, a Personal Computer (PC) 148 is coupled to server 150 via a Socapel control unit 152. The PC 148 programmes the packaging machine 100 based upon control data received via the server 150 and the Socapel control unit 152.

The packaging machine 100 is programmed to package at least one article in an arrangement required by a user. The programmable aspect of the packaging machine 100 allows different types of packaging to be employed, for example end-loaded carriers, wrap-around packages and/or basket carriers. The carton blank corresponding to the type of package required is merely placed in the hopper 102. If a variety of different articles need to be packaged, sets of different articles can be loaded onto the article conveyor 110 either in series or in parallel for positioning by the article transfer apparatus 108.

In operation, carton blanks are fed into the hopper 102 and individually taken from the hopper 102 by the rotary feeder 104. The rotary feeder 104 feeds the carton blanks onto the in-feed conveyor 106, where the package blanks are conveyed to the article transfer apparatus 108. According to the control data received, the first and second drive motors 406,412 are activated and the guide means moved to position at 416 so that at least one article is taken from the terminus 404 of the article conveyor 110 and placed in at least one respective position 418 in a positioning region 420 at the loading point.

One advantage of this approach is that individual or small groups of articles can be moved to particular positions at the loading station. This means that if it is desired to load different types or sizes of articles, they can be conveyed to the correct position for loading-thereby increasing the flexibility of the system. In order to select the correct article for the array, the different articles are loaded onto the conveyor and a sensor or other detection device identifies the article to be transferred.

Once a desired number of articles have been arranged, a carton blank is picked up and moved, in this example, over the arranged articles at the article transfer apparatus 108 by the robotic blank manipulator 116. Based upon the control data employed, the first, second and third arm shafts 134,136, 138 are rotated about the first guide shaft

arrangement 122, the separation between the first coupling part 130 and the second coupling part 132 being adjusted so as to lower or raise the hand portion 200 as required. The first arm 116 is also translatable along the first guide shaft arrangement 122 as dictated by the control data.

Similarly, depending upon the control data employed, the hand portion 200 is made to rotate about an axis perpendicular the longitudinal axis of the second arm shaft 138 and the first and second suction cups 206,210 and the first and second lugs 208,212 are made to translate along the hand support frame 204 as required. Additionally, the suction cups 206, 210 can be made to translate in a manner already described above.

The second arm 128 can be controlled in an analogous manner to the first arm 126, but independently of the first arm 126 if required. The various motors described above and the first and second suction cups 206,210 are activated and/or deactivated in accordance with the control data so as to assemble the package blank, in this example about the at least one object to be packaged.

Examples of the movement of robotic blank manipulators are provided in Figures 6 to 8 for loading wraparound, and loaded and basket carriers respectively.

In Figure 6, there is shown a wraparound carton blank B which is transferred from the infeed by both arms 126 and 128 engaging opposed side panels. The blank B is transferred to the loading station and the articles are inserted into the openings O (Step 1). Then the sides are folded by pivoting the suction cups 216 inwardly about pivot 216 (Step 2). The loaded package B is then conveyed to the base panel securing station 144 by the arms 126 and 128 and the trailing lug 115 is brought into contact with the rear of the package to help move it forward (Step 3). As the package moves towards station 144, fixed guides 142 fold base panels inwardly (Step 4). As well as controlling the motion of the arms, the controller will determine the position of the suction cups as they engage the blank, the position and order of the article array and the movement of the other sub-assemblies of the machine.

The construction of the basket carrier is illustrated in Figure 7, whereby one of the arms 128 picks up the basket carrier blank B by engaging with one of the side walls (Step 1).

The suction cup 216 is pivoted inwardly to move the blank into the vertical plane (Step 2) and the other arm 126 is moved into position to engage the opposing side wall (Step 3). The opposing side walls are moved apart by moving the arms 126, 128 apart, and moving one arm laterally with respect to the other when it is required to erect a parallelepiped carrier (Step 4). The carrier B is the moved by the arms 126, 128 over the articles and lowered by relative vertical movement between blank and articles (Step 5). Thereafter the trailing lug 115 is brought into contact with the carrier and the carrier is moved to the base securing station by the arms 126,128 and the trailing lug 115 (Step 6).

The fully enclosed carton is formed by reference to Figure 8, whereby both arms 126 and 128 abut the top panel and the base is retained by another engaging means, for example a suction cup. The suction cups on the arms engage the top panel and the arms are raised in unison to separate the top from the base (Step 1). The leading and trailing lugs 113,115 are moved into abutment with opposing side walls to be engaged therewith and the articles A are loaded (Step 2). In order to close the end panels, the arms 126,128 are moved around to the opposing ends and the suction cups 216 moved to inoperative positions. The guides 208/212 are moved to operative positions and fold the rear support panel inwardly (in those embodiments with this construction) while the front support panel is folded inwardly by a fixed guide 142 as the carton is moved forward by the leading and trailing lugs 113,115 (Step 3). Thereafter the upper end panels are folded downwardly by the guides 208/212 and the lower end panels are folded upwardly by fixed guides during forward movement of the carton (Step 4).

Numerous other configurations of moving the manipulator and leading and trailing lugs can be programmed into the controller so that the machine is able to erect, fold and load a wide range of cartons and carriers with minimal downtime between changeover from one carton type to another.

Turning again to Figure 1, once assembled and loaded, the package is conveyed by the manipulator to the next station which, in this apparatus, is to fold and secure base panels together. Therefore the package passes through the fixed guides 142 in order to fold the base panels of the carton blank so as to prepare the package for locking.

The substantially assembled package with the article array contained therein is then passed to the station for securing the base panels together. In this embodiment the lock punch mechanism 144 is used as is well known in the art, whereby the locks formed in the carton blank, thereby securing articles within the package. Once locked, the package is conveyed by the out-feed conveyor 146 away by the robotic blank manipulator 116 and out of the packaging machine 100.

Various aspects of the machine, for example the manipulator 116 or the article transfer apparatus 108 can be fitted to other types of known packaging machines, either new ones or existing machines on a retrofit basis.

Modifications may be made without departing from the scope of the present invention.

In particular, alternate sensors and alternate means of positioning each of the moveable articles, or feeding the blanks, may be utilised without departing from the scope of the invention as claimed in the accompanying claims.

In addition, while the preferred embodiment described herein is for loading bottles into cartons, it will be recognised that the invention is not limited to cartons for bottles or cans. The invention may be used with machines for packaging cans, paperboard "bricks"and other containers into cartons. Further, the present invention is able to process cartons comprising numerous configurations of groups of articles covering a range of carton size and shape, for example four, six; eight and twelve bottles without undue time being spent in adjusting the mechanism.