The invention relates to a semi-automated device for the manufacturing of storage bags made from tubular fabric and in particular to a semi-automated liner insertion device (or an apparatus), and a semi-automated method of inserting a liner cut piece into an outer covering, for making composite storage bags where storage bags have a liner inserted into them.

Background Of Invention:

The composite storage bags referred to herein this description are used to store hydroscopic materials which are likely to absorb but need to be protected from moisture from atmosphere, where liner acts as a moisture barrier. At present composite bags with liner are made by manual process which has very low productivity, labour intensive and is fully dependent upon operator. In some fully automated processes, the liner is mechanically inserted into outer bags, but such processes have a drawback of lower efficiency during downstream hemming of bags produced using such processes. For better efficiency in hemming process, the liner mouth has to be pre-opened which is not possible in the known automated process.

Therefore, there is a need to provide a device and a method to overcome these drawbacks. In particular, there is a need to provide a method that produces a composite bag comprising an outer covering and a liner insert such that it maintains integrity of the liner, thereby making it suitable for specific storage applications including storage of perishable goods. There is also a need to provide a process that allows the flexibility of stitching the liner insert along with the stitching of the outer covering or stitching the outer covering without stitching the liner insert along with it. Objects of Invention:

Accordingly, the main object of the invention is to provide a semi-automated method of making a composite bag comprising an outer covering and a liner insert.

Another object of the invention is to provide a semi-automated method to make composite bags such that the integrity of the liner is not destroyed during the insertion process.

Another object of the invention is provide an automated device for inserting liner into outer covering of composite bags.

A further object of the invention is to provide a semi-automated method of making composite bags such that it allows a downstream process whereby flexibility is afforded of stitching the liner insert along with the stitching of the outer covering or stitching the outer covering without stitching the liner insert along with it.

Brief Description of Figures:

Figure 1 shows an outline of the device made for the purpose of liner insertion and mounted on a height adjustable frame

Figure 2 shows the stage whereby the liner insert is beginning to be placed over the liner insertion platform which is actuated by a pressure foot pad,

Figure 3 shows the stage whereby the liner insert is fully placed over the liner insertion platform as it completes its forward movement

Figure 4 shows the fully extended position of the liner insertion platform with liner on which the outer covering is placed manually (indicated by hands) Figure 5 and 6 shows the liner insertion platform of Figures 1 to 4 being retracted to its original position and the composite unstitched bag being helped onto the stacking platform.

Figure 7 shows a schematic of the pneumatic circuit/activation device with spring return foot pad valve

Figure 8 shows a schematic of the pneumatic circuit/activation device with electrically or electronically actuated solenoid valve

Summary of Invention:

The semi-automated liner insertion device comprises the following key parts: a height adjustable frame (10) on which the liner insertion platform (1) is mounted. The frame (10) also comprises a pair of rails (3) onto which a cross member (2) that is connected to the liner insert platform (1) may move. an automated pneumatic system by which the forward and backward movements (M _F and M _B ) of the liner insertion platform (1) in its own plane is facilitated using a pneumatic cylinder (8)

A stacking platform (7) to receive the composite unstitched composite open bag (6) comprising outer covering and a liner insert. The stacking platform (7) is placed substantially beneath the extended position of the liner insertion platform (1).

The semi-automatic device of the invention facilitates an automated movement of the liner insertion platform (1) onto which a liner cut piece (4) is placed manually, followed by placement of an outer covering piece (5) on the liner cut piece (4).

Details of all other parts that comprise the device of the invention are disclosed in the detailed description. The invention also discloses a method of inserting a liner cut piece (4) into an outer covering (5). The method uses the device of the invention and comprises the following broad steps:

• Keeping the pneumatic cylinder (8) in a retracted position, · Inserting the mouth of liner cut piece (4) over the liner insertion platform (1), and pressing the foot pad (9) so that the pneumatic cylinder (8) moves in a forward movement (M _F ) to the extended position, and the liner insert (4) gets placed over the liner insertion platform (5).

• Manually inserting an outer covering cut piece (5) over the liner cut piece (4) and releasing the pressure from the foot pad (9) so that the backward movement (M _B ) of the pneumatic cylinder is effected to its retracted position.

Details of all other operational steps of the device of the invention are disclosed in the detailed description.

List of Parts:

1 - Semi-automated liner insertion platform,

1A - front end of the liner insertion platform, IB - recess - IB, 1C and ID - side arms of the liner insertion platform; front arm of the liner insertion platform - IE

2 - Cross member, 2A - rolling or sliding mechanism

3 - Rail (i.e. Guide rod and linear bearing arrangement)

4 - Liner cut piece, 4A - front end of liner cut piece, 4B - back end of liner cut piece 5 - Outer covering cut piece, 5A - back end of outer covering piece, 5B - front end of outer covering piece

6 - Composite open bag

7 - Stacking platform

8 - Pneumatic cylinder

9 - Pneumatic valve foot pad 10 - Height adjustable base Frame

11 - Stiffening members

12 - Spring base foot-pad operated pneumatic valve

13- Electrically or electronically operated solenoid valve

14 - Air supply

15 - Pneumatic circuit/ activation device

16 - Proximity sensor M _{F -} forward movement M _{B -} backward movement

Detail Description of Invention:

A semi-automatic or semi-automated device for inserting liner cut pieces (4) or liner bags into outer covering cut pieces (5) or outer bags is disclosed. Pillow shaped storage bags for storing materials that need to be protected from moisture are often provided with a liner made of material which is impervious to moisture. The invention provides a semiautomatic device which has a semi-automated movement of a liner insertion platform (1) onto which a liner cut piece (4) is placed manually, followed by placement of an outer covering piece (5) on the liner cut piece (4). Details of the device and its operation, and the method of inserting an outer covering piece (5) onto a liner cut piece (4) are now provided.

The semi-automated device of the invention discloses a preferably a semi- automated C-shaped liner insertion platform (1) that is capable of movement in direction parallel to the plane of the platform. As shown in Figure 1, the horizontal movement of the liner insertion platform (1) is made possible by a cross member (2) that is fabricated using plates structure made up of structure steel and which is connected to the liner insertion platform (1). The cross member (2) moves on a pair of rails (3) which form a part of the height adjustable frame (10). The cross member (2) is provided with a sliding or rolling mechanism (2A) that is known to a person skilled in the art that allows it to roll or slide over the rails (3). The rolling or sliding mechanism (2A) rolls or slides over the rails (3) as the cross member (2) gets pushed or pulled by the pneumatic cylinder (8), which is connected at one end to said liner insert platform (1) and at other end to an actuating device or a activation device (15) for controlling said forward and backward movements (M _F and M _B ). The activation device (15) for controlling forward and backward movements (M _F and M _B ) operates on two alternative principles: a. The activation device (15) consists of a pneumatic valve (12) operated by a spring based foot-pad (9) which supplies pneumatic pressure to said pneumatic cylinder (8). Alternatively, b. The activation device (15) consists of a solenoid valve (13) which is actuated by an electrical signal generated from a proximity sensor (16) that is operated electrically or electronically, which supplies pneumatic pressure to said pneumatic cylinder (8), and wherein said sensor (16) is capable of sensing the operator’s hand and giving a signal to the solenoid valve (13) for its actuation

Most of the next part of the operation of the device is explained on the basis of the alternative a.

Rails (3) are solid or hollow bars, preferably made of high carbon steel with hard chrome plating to avoid wear. The movement of the liner insertion platform (1) is controlled by pneumatic foot pad (9) which is linked with pneumatic cylinder (8) that is connected with liner insertion platform (1).

At the start of the operation of making a combine (6) of an outer covering (5) into which a liner (4) is inserted, the liner insertion platform (1) is kept in the retracted position (see Figures 1 and 2) (also termed as the zero position or the starting position). At this point, the front end (4A) of the cut liner piece (4) that is sealed at one end is held in front of the front end (IE) of liner platform (1A) manually (see Figure 2). Much of the liner cut piece (4) remains hanging under its own weight in a drooped positon. Next, the liner cut piece (4) is manually held by both sides (see Figure 3), whereafter the pneumatic cylinder (8) is actuated by pressing the foot pad (9). The pressing of the foot pad activates the pneumatic circuit (15), which ultimately enables travel of pressurised air to the pneumatic cylinder (8) to commence its forward movement (M _F ) which in turn causes the liner insertion platform (1) to commence its own forward movement (M _F ).

In order to facilitate the ease of operation of inserting the liner cut piece (4) over the semi-automated liner insertion platform (1), the liner cut piece (4) is manually lifted at both its sides from its drooped position to bring it substantially in the plane of the moving liner insertion platform (1). The liner insert platform (1) is now optionally moved forward at a greater speed by a predetermined distance, which is determined based on the overall length of the cut piece of the liner (4). Specifically, the total distance that the liner insertion platform (1) travels is substantially the same as the length of the liner cut piece (4). At the end of the forward movement (M _F ) of the liner insertion platform (1), the device optionally sends a signal such as an audio alarm so that the operator of the device becomes aware of the stoppage of the forward movement (M _F ). At this point the liner insert or the liner cut piece (4) is completely, that is for its entire length, placed over the liner insertion platform (1) (see Figure 3). The operator ensures that the sealed end (back end 4B) of the liner cut piece (4) is secured against the front end (1A) of the liner insertion platform (1).

Next, as shown in Figure 4, an outer covering piece (5) that is sealed at its one end (back end 5A) is picked up by the operator from a stack (not shown) of outer covering pieces, and inserted from its open end (front end 5B) for its entire length over the liner cut piece (4) that is already inserted over the liner insertion platform (1). The operator ensures that the outer covering piece (5) is also extended to the maximum possible distance (i.e. the entire length of it) so that it cannot move any further during the insertion process. At this stage a composite open bag (6) (or a combine) is formed comprising the outer covering (5) into which and the liner cut piece (4) is inserted. In other words, the composite open bag (6) (or the combine) is inserted over the liner insertion platform (1).

The outer cut piece (5) is preferably pre-stitched or sealed at its one end (the back end 5A) thus allowing the liner cut piece (4) to be placed loosely inside it. There are situations where the bag makers may prefer that the liner cut piece (4) is left open at both ends and that it is stitched together with the outer covering (5) once the liner (4) is placed inside the outer covering (5). Optionally, therefore, either the liner cut piece (4) or the outer covering piece (5) or both of them may have both ends open so that liner (4) can be stitched later together with outer covering (5) to make a robust composite bag.

Once the outer covering (5) is fully placed on the liner insert cut piece (4), the backward movement (M _B ) of the liner insertion platform (1) commences by removing the pressure from foot pad (9) and thereby retracting the pneumatic cylinder (8) that is connected with liner insertion platform (1). Optionally, there is provided a first time gap between the end of the forward movement (M _F ) and the commencement of the backward movement (M _B ).

Depending on the actual internal size of the liner insert cut piece (4) and the overall dimensions of the liner insert platform (1), the combine (6) may be placed slightly tight over the liner insertion platform (1). During the backward movement (M _b ), this may cause the combine (6) to get stuck or adhered to the liner insertion platform (1) and move along with it. In order to ensure this does not happen, the combine (6) is held by an operator (not shown) so that it does not move backward along with the liner insertion platform (1). To achieve this, the operator must ensure that both components of the combine (6) - that is the outer covering (5) and the liner insert (4) - are held securely. As the backward movement (M _B ) of the liner insertion platform (1) continues, the composite open bag (6) thus gets removed from the liner insertion platform (1). The process of removal of the composite open bag (6) from the liner insertion platform (1) may optionally be aided by the operator positively pulling the composite open bag (6) in the forward movement direction (M _F ).

Once the composite open bag (6) is completely out of the liner insert platform (1), the operator releases it and it falls on its own onto a stacking platform (7) provided to stack the combines (6). Optionally, the operator may guide the falling combines (6) onto the stacking platform (7).

Once the composite open bag (6) is stacked, or at any suitable time such that another composite open bag (6) may be formed, the liner insertion platform commences (1) its next forward movement (M _F ). There is optionally provided a second time gap between when the backward movement (M _B ) of the insertion platform (1) is completed and the forward movement (MF) of the next cycle begins. The time gap may only be of a fraction of a second to a few seconds. This is because composite bag (6) needs to be completely removed from the insertion platform (1) by holding composite bag (6) during backward movement and ensure that it is stacked properly on the stacking platform, only after which the new cycle of liner insertion may begin. The time gap may be adjusted by the operator.

To facilitate a grip by the operator on the composite open bag (6) for its removal from the liner insert platform (1), the liner insert platform (1) may be provided with a recess (IB) along at least any one of its three accessible sides: these are left and right side arms (1C, and ID) and the front side (IE). Preferably the recess (IB) is provided near the centre of the front side (IE) (see Figure 6). Gripping the combine (6) from near centre of the front side (IE) has the advantage that minimal relative motion takes place between the outer covering (5) and the liner insert (4) so that there is least amount of disturbance in the relative alignment of the outer covering (5) and the liner insert (4). While it is possible to grip the combine (6) at one of the two corners of the combine (6), it is less preferable as there are chances that alignment of the liner insert and outer covering (4 and 5) may be disturbed depending on the operator skill. Further, gripping the combine (6) at both its corners may provide a satisfactory result, however, it requires the operator to use both hands, which is less preferable.

In another aspect of the invention, in accordance with the alternative principle b of operating the actuating device for controlling forward and backward movements (M _F and M _b ), the actuating device consists of a solenoid valve (13) which is actuated by an electrical signal generated from a proximity sensor (16) that is operated electrically or electronically, which supplies pneumatic pressure to said pneumatic cylinder (8), and wherein said sensor (16) is capable of sensing the operator’s hand and giving a signal to the solenoid valve (13) for its actuation. The sensor (16) may be placed on the base frame (10) within the reach of the operator.

In one aspect of the invention, the liner insertion platform (1) may be in a different plane than that of the rails (3).

In another aspect of the invention, the height of the insertion platform (1) from ground is adjustable using the height adjustable frame (10) on which it is mounted. This has the advantage that the level or height of the liner insertion platform (1) can be adjusted to the comfort of the operator.

The method of liner insertion thus comprises the following broad sequential steps:

- Providing a device made for the purpose of liner insertion,

- Keeping the liner insertion platform (1) in a retracted position,

Manually holding the liner insert (4) with its open front end (4A) in front of the front end (IE) of the liner insertion platform (1), - Extending the pneumatic cylinder (8) to cause the liner insertion platform (1) to move in a forward direction (M _F ) such that the front end (IE) of the liner insertion platform (1) enters the front open end (4 A) of the liner insert (4) and stopping the movement of the liner insertion platform (1) once the front end (IE) reaches its desired extended position,

- Manually picking up the outer covering (5) and placing it over the liner insert (4) that is already positioned over the liner insertion platform (1), thereby forming the composite bag (6) (or the combine)

- Manually holding together the back end of the combine (6) followed by retracting the liner insert platform (1) in a backward movement (M _B ) which commences by the removal of pressure from the foot pad (9), Allowing the composite open bag (6) - i.e. the outer covering with the liner insert placed inside it - to get stacked on the stacking tray (7). Detailed steps of the method of invention are as follows: a. providing a semi-automated device as described herein, b. keeping the liner insertion platform (1) in a retracted position, c. manually holding the liner insert cut piece (4) with its open end in front of the front end (IE) of the liner insertion platform (1), d. commencing the forward movement (M _F ) of said liner insertion platform (1) by actuating the pneumatic cylinder (8) causing the cross bar (2) to start the forward movement (M _F ), e. ensuring that the front end (IE) of the liner insertion platform (1) enters the front end of liner cut piece (4), f. continuing the forward movement (M _F ) of the liner insertion platform (1), g. automatically stopping the moving liner insertion platform (1) once the forward movement (M _F ) completes a predetermined distance, h. providing a first time gap before the backward movement (M _B ) begins, i. manually picking up the outer covering (5) and placing it over the liner insert (4) that is already positioned over the liner insertion platform (1) so that a combine (6) of the outer covering (5) and the liner cut piece (4) is formed, j . manually holding together the back end of the combine (6), k. actuating the reverse movement of the pneumatic cylinder(8) to commence the backward movement (M _B ) of the liner insert platform (1) to bring it out of the combine (6), l. completing the backward movement and allowing a second time gap before forward movement (M _F ) of the next cycle begins, m. allowing the combine (6) to get stacked on the stacking tray (7).

In one embodiment of the method of invention, the speed of forward movement (M _F ) in steps d, e, and f is the same.

In another embodiment of the method of invention, the first and second time gaps are a fraction of second.

In a still further embodiment of the method of invention, after said step a, the height of the liner insertion platform is adjusted by the operator.

In another embodiment of the method of invention, the manual holding together of the back end of the combine (6) is carried out near the middle of said front end (IE) of said liner insertion platform (1).

In yet another embodiment of the method of invention, said liner cut piece (4) and/or said outer covering (5) is sealed before their insertion over the liner insertion platform (1).

In still another embodiment of the method of invention, said forward and backward movements (M _F and M _B ) are effected by supplying pneumatic pressure to said pneumatic cylinder (8) via a pneumatic valve (12) operated by a spring based foot-pad (9).

In a further embodiment of the method of invention, said forward and backward movements (M _F and M _B ) are effected by supplying pneumatic pressure to said pneumatic cylinder via a solenoid valve (13) which is actuated by an electrical signal generated from a proximity sensor (16) that is operated electrically or electronically, said sensor (16) capable of sensing the operator’s hand and giving a signal to the solenoid valve (13) for its actuation.

In a still further embodiment of the method of invention after step g, said device sends an audio alarm indicating the stoppage of the forward movement (MF).

In one embodiment of the device of invention, the plane of movement of the liner insertion platform may be oriented at any angle with the horizontal. In this embodiment, the orientation of the side rails (3) is provided suitably to facilitate backward and forward movements (M _B and M _F ) of the liner insertion platform (1).

The semi-automated liner insertion device of the invention has the capability to produce 13-15 bags/min in comparison to 8-10 bags/min that conventional fully manual liner insertion machine are capable of producing.

In one example, storage bags were made from tubular fabric of Polypropylene material of size 580mm width and 900mm length in which a liner made from polyethylene material of size 600mm width and 1000mm length was required to be inserted and in particular to a device or an apparatus of and method for making composite storage bags where storage bags have a liner inserted into them. The liner insertion platform was made using fabrication of structure steel. During the forward movement (MF), the insertion platform was moved at a speed of 1 m/s. The duration of stoppage of the platform movement between the forward and backward movements (MF and MB) was 1.5 second. During the backward movement (MB), the insertion platform was moved at a speed of 0.9m/s. The duration of stoppage between two consecutive cycles was 1 seconds. In another example, storage bags were made from tubular fabric of Polypropylene material of size 600mm width and 960mm length in which a liner made from polyethylene material of size 640mm width and 1060mm length was required to be inserted and in particular to a device or an apparatus of and method for making composite storage bags where storage bags have a liner inserted into them. The liner insertion platform was made using fabrication of structure steel. During the forward movement (MF), the insertion platform was moved at a speed of 1 m/s. The duration of stoppage of the platform movement between the forward and backward movements (MF and MB) was 2 second. During the backward movement (MB), the insertion platform was moved at a speed of 0.9m/s. The duration of stoppage between two consecutive cycles was 1.5 seconds.

While the above description contains much specificity, these should not be construed as limitation in the scope of the invention, but rather as an exemplification of the preferred embodiments thereof. It must be realized that modifications and variations are possible based on the disclosure given above without departing from the spirit and scope of the invention. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.