DESC:FIELD OF THE INVENTION
The present invention generally relates to the field of industrial automation in the packaging industry, and more particularly, to a packaging substrate erector and flattener device for forming/deforming cartons, automatically, in various shapes and sizes, and a method of erecting a packaging substrate.
BACKGROUND
With the advent of advancement in technology and digitalization, there has been a significant increase in demand in the packaging industry. For example, there has been a significant increase in services provided by e-commerce platforms driving the FMCG and Pharma industry, which directly increases the supply of cartons in the packaging industry. These platforms play a crucial role in simplifying people's lives by granting them access to a wide range of items and products through digital technology.
For instance, with the rapid advancement of digitalization, numerous e-commerce platforms have emerged, offering customers a greatly enhanced experience. These platforms enable individuals to effortlessly order products from across the globe and have them conveniently delivered to their doorstep. This not only provides convenience to users but also saves a considerable amount of time. To illustrate, a user can now use their mobile phone to place orders for food, clothing, medicine, essential items, and more with just a single click.
Furthermore, logistics also assumes a pivotal role in meeting user demands, encompassing activities such as carton usage, product packaging, and shipping. Specifically, the production of cartons for packaging products/items is a critical component of the logistics process. Given the substantial variation in product types, sizes, and specifications, manufacturing cartons in diverse sizes and shapes to cater to these needs presents a significant challenge.
Currently, existing technology includes carton erectors that operate in a specific manner to pick up flat cartons and convert them into fully formed ones. This existing technology is used in custom-designed systems comprising numerous components, multiple pneumatic tubes, and separate control systems in a carton manufacturing unit. Furthermore, to accommodate different carton sizes within a specified range, customized units must be manufactured to suit each of the various carton sizes. As a result, it leads to larger and heavier devices with higher increased manufacturing and assembling costs, extended timeframes, increased workforce demands, and various other ancillary factors.
Therefore, there exists a need to develop an integrated apparatus or system that not only automatically forms processed or final cartons of varying sizes and shapes but simultaneously reduces the number of components of said apparatus and enhances the overall efficiency of manufacturing or the forming of cartons.
OBJECTS OF THE INVENTION
In view of the shortcomings of the existing systems, there exists a need for an integrated apparatus that automatically fetches a flat packaging substrate and transforms it into a carton or fully assembled boxes or vice versa.
It is an object of the present disclosure to develop a packaging substrate erector and flattener device that forms three-dimensional cartons of varying shapes and sizes.
It is another object of the present disclosure to develop a device that automatically erects or forms flat-packed cardboard cartons into fully assembled boxes, reducing the need for manual labor.
It is another object of the present disclosure to develop a packaging substrate erector and flattener device that allows for adjusting automatic adjusting of different components of the device depending on the desired size of the three-dimensional carton to be formed.
It is another object of the present disclosure to develop a packaging substrate erector and flattener device that allows for real-time monitoring and control of the carton erection process, thereby enabling quick adjustments and optimizations as needed.
It is another object of the present disclosure to develop a packaging substrate erector and flattener device to improve the speed and consistency of carton formation to match high-volume production lines.
It is another object of the present disclosure to develop a device to ensure compatibility with existing packaging systems, conveyor systems, and robot/gantry/mechanical chain linkage.
It is another object of the present disclosure to develop a device to fold the packaging substrate precisely reducing the risk of misaligned or damaged packaging.
It is another object of the present disclosure to provide a cost-effective device that reduces the manual labour costs and time.
It is another object of the present disclosure is to provide an environmentally friendly single device that eliminates the need for multiple erector devices, as the present disclosure can handle a wide range of shapes and sizes of packaging substrate.
It is another object of the present disclosure to develop a device to provide uniformly erected cartons with reduced packaging defects.
It is another object of the present disclosure is to develop a sustainable device manufactured predominantly using additive manufacturing that enables building a complex design while also requiring less material and leading to lower material wastage.
It is another object of the present disclosure is to provide a lightweight product that is structurally strong while also leading to less energy used operationally.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated herein, and constitute a part of this invention, illustrate exemplary embodiments of the disclosed methods and systems in which, like reference numerals refer to the same parts throughout the different drawings. Components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Some drawings may indicate the components using block diagrams and may not represent the internal circuitry of each component. It will be appreciated by those skilled in the art that disclosure of such drawings includes disclosure of electrical components or circuitry commonly used to implement such components. Although exemplary connections between sub-components have been shown in the accompanying drawings, it will be appreciated by those skilled in art that other connections may also be possible without departing from the scope of the invention. All sub-components within a component may be connected to each other, unless otherwise indicated.
FIG.1A illustrates a front view of a packaging substrate erector and flattener device, in accordance with various embodiments of the present disclosure.
FIG.1B illustrates a top view of the packaging substrate erector and flattener device, in accordance with various embodiments of the present disclosure.
FIG.1C illustrates a perspective view of an exemplary embodiment of the packaging substrate erector and flattener device with an extension portion in the extended position and the arm rotation from inward position to horizontal position, in accordance with various embodiments of the present disclosure.
FIG.1D illustrates a perspective view of another exemplary embodiment of the packaging substrate erector and flattener device with arm in the horizontal position, in accordance with various embodiments of the present disclosure.
FIG.1E illustrates a front view of an exemplary embodiment of the packaging substrate erector and flattener device with inverse gripper ports on the extension portion and the arm, in accordance with various embodiments of the present disclosure.
FIG.1F illustrates a inward perspective view of the packaging substrate erector and flattener device with laser aligner between extension portion and housing, in accordance with various embodiments of the present disclosure
FIG.1G illustrates a perspective view of the packaging substrate erector and flattener device with extension portion and arm in horizontal position, in accordance with various embodiments of the present disclosure.
FIG.1H illustrates a downward perspective view of packaging substrate erector and flattener device, in accordance with various embodiments of the present disclosure.
FIG.1I illustrates a bottom view of the packaging substrate erector and flattener device, in accordance with various embodiments of the present disclosure.
FIG.1J illustrates a side view of the packaging substrate erector and flattener device with arm in the horizontal position, in accordance with various embodiments of the present disclosure.
FIG.1K illustrates another side view of the packaging substrate erector and flattener device with arm in the horizontal position, in accordance with various embodiments of the present disclosure.
FIG.1L illustrates a front view of the packaging substrate erector and flattener device depicting arm movement from downward position to horizontal position, in accordance with various embodiments of the present disclosure.
FIG.1M illustrates a top view of packaging the substrate erector device with robotic coupling plates, in accordance with various embodiments of the present disclosure.
FIG.1N illustrates an exploded perspective view of a portion of the packaging substrate erector and flattener device showing a silencer, ejector retainer and vacuum generator, in accordance with various embodiments of the present disclosure.
FIG.1O illustrates a front perspective view of the packaging substrate erector and flattener device with a pneumatic cable, in accordance with various embodiments of the present disclosure.
FIG.1P illustrates a top view of the packaging substrate erector and flattener device with speed controllers, in accordance with various embodiments of the present disclosure.
FIG.1Q illustrates a front view of the packaging substrate erector and flattener device illustrating opening of arm cap to adjust or remove the arm from the main body, in accordance with various embodiments of the present disclosure.
FIG.1R illustrates a top view of the arm of the packaging substrate erector and flattener device illustrating attachment of the arm at another position in the main body arm cap, in accordance with various embodiments of the present disclosure.FIG.1S illustrates an exploded perspective view of the packaging substrate erector and flattener device, showing the removal of suction cup and Allen key, in accordance with various embodiments of the present disclosure.
FIG.1T illustrates an exemplary embodiment of the packaging substrate erector and flattener device with extension portion in extended position, in accordance with various embodiments of the present disclosure.
FIG.1U illustrates another exemplary embodiment of the packaging substrate erector and flattener device, in accordance with various embodiments of the present disclosure.
FIG 1V illustrates a front perspective view of the packaging substrate erector and flattener device, in accordance with various embodiments of the present disclosure.
FIG. 1W illustrates a downward perspective view of the packaging substrate erector and flattener device, in accordance with various embodiments of the present disclosure.
FIG. 1X illustrates a cam on which the packaging substrate is transported and a taping head for taping the packaging substrate, in accordance with various embodiments of the present disclosure.
FIG. 1Ya illustrates a front perspective view of the packaging substrate erector and flattener device illustrating closure of carton from left to right, in accordance with various embodiments of the present disclosure.
FIG. 1Yb illustrates a front perspective view of the packaging substrate erector and flattener device illustrating closure of carton from right to left, in accordance with various embodiments of the present disclosure.
FIG.1Z illustrates a flowchart depicting a method of erecting a packaging substrate or manufacturing a carton, in accordance with various embodiments of the present disclosure.
The foregoing shall be more apparent from the following more detailed description of the invention.
DESCRIPTION OF THE INVENTION
Exemplary embodiments now will be described with reference to the accompanying drawings. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this invention will be thorough and complete, and will fully convey its scope to those skilled in the art. The terminology used in the detailed description of the particular exemplary embodiments illustrated in the accompanying drawings is not intended to be limiting. In the drawings, like numbers refer to like elements.
The specification may refer to “an”, “one” or “some” embodiment(s) in several locations. This does not necessarily imply that each such reference is to the same embodiment(s), or that the feature only applies to a single embodiment. Single features of different embodiments may also be combined to provide other embodiments.
As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “include”, “comprises”, “including” and/or “comprising” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. Furthermore, “connected” or “coupled” as used herein may include wirelessly connected or coupled. As used herein, the term “and/or” includes any and all combinations and arrangements of one or more of the associated listed items.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
The figures depict a simplified structure only showing some elements and functional entities, all being logical units whose implementation may differ from what is shown. The connections shown are logical connections; the actual physical connections may be different.
In addition, all logical units described and depicted in the figures include the software and/or hardware components required for the unit to function. Further, each unit may comprise within itself one or more components, which are implicitly understood. These components may be operatively coupled to each other and be configured to communicate with each other to perform the function of the said unit.
In the following description, for the purposes of explanation, numerous specific details have been set forth in order to provide a description of the invention. It will be apparent, however, that the invention may be practiced without these specific details and features.
Fig. 1 illustrates an integrated carton erector device, particularly, a pneumatic carton erector device 100 according to various embodiments of the present disclosure. The present invention provides an integrated pneumatic carton erector device 100 that receives a two-dimensional carton transforms it into a three-dimensional carton. The device 100 may include a main body 6, a sub housing 16 that includes an arm and an extension portion, which are configured to grip or release the carton using pneumatic and electrical communication. The device can adapt to different sizes of carton by changing the position and orientation of the main body, the arm and the extension portion. Further, the integrated pneumatic carton erector has a modular design that enables the functioning of using different parts (such as the main body, the arm and the extension portion) interchangeably to form the carton of the desired shape and size. Furthermore, the adjustable functionality of the pneumatic carton erector device also helps in forming the carton of the desired sizes by varying the position of vacuum cups. For instance, one of the inverse gripper ports or vacuum/suction cups may be extended to the desired distance to form carton of bigger sizes.
Figs. 1A to 1P illustrates different views of the same pneumatic carton erector device 100 having similar or substantially similar components which have not been repeated with respect to each of the illustrated figures for the sake of brevity.
Further, in Fig. 1A-1P, only single components are shown, however, the pneumatic carton erector device 100 may comprise multiple components, units, and modules or may comprise any such numbers of said units and modules, as may be required to implement such features of the present invention. Further, there may be one or more sub-units of said units and modules of the pneumatic carton erector device 100, and the same is not shown in the Fig. 1A-1P for sake of clarity.
According to an embodiment of the present disclosure, the present invention discloses an integrated carton erector device, particularly, a pneumatic carton erector device 100 that automatically fetches a flatly packed two-dimensional carton and transforms it into a formed three-dimensional carton of varying shapes and sizes.
As used herein, a carton refers to a box or container made of corrugated paperboard or cardboard for packaging various products, goods, or items. The pneumatic carton erector device is designed to form cartons of customized sizes from a flatly stacked condition into a fully taped and formed 3-dimensional structure. The pneumatic carton erector device has an internal air distribution unit, valves, vacuum generator, and pneumatic cylinders, all integrated and housed in one single unit. Further, the pneumatic carton erector device adjusts the vacuum cup position depending on the size of the carton to be formed. Moreover, the pneumatic carton erector device includes an inbuilt control unit with custom software that simplifies the user’s ability to deploy the system for the required application, without the need for additional hardware or programming. The inbuilt control unit is configured to communicate with a robot/gantry/mechanical chain linkage device that shall be connected with the pneumatic carton erector device, and simultaneously is configured to control and perform overall functions of the pneumatic carton erector device.
In one scenario, when a carton with dimensions of length "l," breadth "b," and height "h" is needed for packaging, the pneumatic carton erector device forms cartons that match these specifications using its components. In another scenario, when a carton with dimensions of length "l + a," breadth "b," and height "h" is required, the same pneumatic carton erector device extends the main body along the horizontal axis and adjusts the positions of the vacuum cups. The pneumatic carton erector device is versatile enough to create containers of different sizes without needing any additional components or units.
As shown in Fig. 1A, the pneumatic carton erector device 100 may include a main housing or a main body 6. The main body 6 may comprise an upper surface, a bottom surface and side surfaces. The side surfaces may include a first side surface, a second side surface, a third side surface, and a fourth side surface, where the first side surface and the second side surface are opposite to each other while the third side surface and the fourth side surface are opposite to each other. As shown in Fig.1B and Fig.1C, the main body 6 may be attached to an arm or extension 16b at the first side surface and an extension portion 16a at the second side surface. The arm 16b may be extended or retracted according to the size of the packaging substrate or carton.
The present disclosure should not be limited to the arrangement of the L-shaped arm 16b and the extension portion 16a on the first to fourth side surfaces of the main body and any combination of the L-shaped arm 16b and the extension portion 16a may be arranged on the first to fourth side surfaces of the main body. As shown in Fig. 1C and Fig.1D, the extension 16b or arm may be an extendable or a retractable portion.
According to an embodiment, the arm 16b may be an L-shaped arm. The L-shaped arm may be extendable/retractable. The L-shaped arm 16b may be rotatably arranged at a first side surface of the carton erector device in a horizontal position as illustrated in Fig. 1C and Fig. 1E and rotated inward as illustrated in Fig. 1D. The arm 16b can extend and retract as needed to handle different carton sizes or adjust to various stages of carton assembly. Initially, the L-shaped arm is positioned horizontally along the first side surface of the carton erector device, as shown in Fig. 1C and Fig. 1E. The description of the particular embodiment is illustrative and should not be construed as limiting the scope of the present disclosure.
In an implementation, when a carton or packaging substrate reaches the folding stage, when the flaps need to be folded down or held in place for secure assembly, the arm 16b rotates inward, as illustrated in Fig. 1D, enabling it to engage with and fold the carton flap precisely. By rotating inward, the arm engages with a carton’s side or top flap, folding it into the correct position.
This extendable/retractable and rotatable functionality allows the arm 16b to adapt to cartons of different dimensions and ensures that the device can form cartons accurately with manual adjustment or automatically.
According to another embodiment of the present disclosure, the arm 16b may include laser aligners 28 for precise positioning of the carton. The laser aligners 28 may be positioned below the arm as illustrated in Fig. 1F, that may be adapted to detect the position of the carton. When the carton is in place, the laser aligners emit beams that detect the carton’s exact position by reflecting off its surface. According to an embodiment, the laser aligner 28 may be positioned at the edge joining the extension portions 16a with the main body 6. By positioning the aligner 28 at the edge, it can monitor the alignment between the carton and the robot/gantry/mechanical chain linkage, especially at critical joining points. As the carton enters the erector, the laser aligner detects its edge position, confirming that it aligns properly with the extension portions and the main body. This process can be achieved both manually or automatically. The description of the particular embodiment is illustrative and should not be construed as limiting the scope of the present disclosure.
According to another embodiment of the present disclosure, the main body 6 may include a sub-housing 16 mounted on the sidesof the main body 6. As illustrated in Fig. 1G, the main body 6 may include a modular coupler 14 that may be attached to the robot/gantry/mechanical chain linkage (not shown in the figures). The modular coupler 14 may be interchanged based on the brand or type of the robot/gantry/mechanical chain linkage being employed. Further, the surface of the main body 6 may include a maintenance hatch that provides access to the silencer 44, pneumatic & vacuum components which may require periodic maintenance.
However, according to another embodiment of the present disclosure, the arm 16b may be arranged at the third side surface or the fourth side surface. By placing the arm 16b on the third or fourth side surface, it can engage with the carton at different points, improving folding precision and alignment depending on the carton’s orientation and the device’s operation requirements.
Further, according to another embodiment of the present disclosure, the extension portion 16b may be arranged at the third side surface or the fourth side surface.
According to another embodiment of the present disclosure, an additional extension portion 16a may be arranged at the third side surface and/or the fourth side surface.
As illustrated in Fig. 1H,1I, 1J and 1K , the main body 6 includes at least one inverse gripper port 12 arranged at the bottom surface. The inverse gripper port 12 may have a suction cup or foam. In a preferred embodiment of the present disclosure, the main body includes four inverse gripper ports arranged at the bottom surface.
According to another embodiment, the arm 16b may be rotatably arranged on the first side surface of the main body 6 using a rotational or prismatic joint 10 (as shown in Fig. 1G). Further, the surface of the main body 6 may include at least one joint speed control 22 configured to control the speed of the rotational or prismatic joint 10 attached to the arm 16b so as to control the movement of the arm 16b. According to another embodiment of the present disclosure, the main body 6 may include an input/output connector 2 that may be configured to receive power supply and I/O communication signals to/from robot/gantry/mechanical chain linkage.
Furthermore, the pneumatic carton erector device includes at least one vacuum generator located inside the main body 6. As illustrated in Fig. 1G herein, the carton erector device 100 may include at least one single compressed inlet 4 for providing compressed air to the vacuum generator 48. The inlet 4 may include a filter for removing dust and other suspended particle received from compressed air or vacuum. Furthermore, the main body 6 may include one or more vacuum generators 48 (as depicted in Fig. 1N) which may be connected to the inverse gripper port(s) or suction port(s) 12. The retainer 46 securely holds the vacuum generator 48 in its position.
The device 100 includes one or more control units (not shown) housed in either the main body 6 or can be added to the sub-housing 16. These control units include both pneumatic control units and electrical control units which work in coordination with each other and with a robot/gantry/mechanical chain linkage. The pneumatic control unit regulates the flow, pressure, and direction of compressed air or vacuum within the device. It adjusts air pressure to an actuator for precise movement and controls vacuum levels to grip or release packaging substrate. The pneumatic control unit controls one or more pneumatic circuitry.
The pneumatic circuitry in the device 100 enables the operation of an inverse gripper mechanism, where the vacuum generator creates suction through the inverse gripper ports for picking the packaging substrate while the actuators facilitate movement of the sub-housing 16 for precise positioning.
The device 100 includes at least one pneumatic circuitry adapted to connect the main body 6 and/or sub-housing 16, a compressed air or vacuum inlet, a vacuum generator, and/or one or more inverse gripper ports and/or one or more actuators and/or other sub-components. The compressed air enters the pneumatic system through the inlet 4. A vacuum generator creates suction force for gripping or holding objects. Actuators adjust the position of the gripper arms to align with the target. The inverse gripper ports quick release the carton or packaging substrate by removing the vacuum in the inverse gripper ports and providing an air blow-off in the same. The device 100 has an electrical control unit (ECU) that serves as the central processor for the device's communication and operation. It performs the role of a master by controlling and coordinating the entire system’s operation. In an example, the robot/gantry/mechanical chain linkage in an automated warehouse handles cartons. The pneumatic carton erector device 100 may be attached to the robot/gantry/mechanical chain linkage, equipped with inverse gripper ports for lifting and moving items. The electrical control unit communicates with the robot/gantry/mechanical chain linkage’s controller to determine when and where to actuate the device. The pneumatic control unit adjusts the suction and release pressure, ensuring that the items are handled safely without damage.
The HMI 3 is positioned on the main body 6 and is connected to the electrical control unit, establishing electrical communication for data exchange. HMI 3 (as shown in Fig 1B and 1E), allows an operator to monitor and adjust parameters such as grip strength or timing directly, providing real-time control. For example, if a packaging process encounters an error, such as insufficient vacuum pressure or a misaligned substrate, the sensors detect the issue and communicate it to the electrical control unit. The control unit then sends the relevant data to the HMI, which displays the error along with potential corrective actions.
The ECU can perform the role of a slave by receiving commands from an external system like a robot, gantry, mechanical chain linkage, or HMI (Human-Machine Interface), and executing those commands.
Alternatively, the vacuum generator may be an external vacuum generator that is routed to the pneumatic carton erector device. Alternatively, the at least one vacuum generator can be a combination of both the internal vacuum generator and the external vacuum generator. Further, the vacuum generator uses compressed air to create suction. Furthermore, the pneumatic and electrical circuitry is designed to create both vacuum or air blow-off or both through at least one of the inverse gripper ports to enable the functioning of the vacuum generator. The functioning of the vacuum generator enables the main body and the sub-housing to grip or release the carton.
As shown in Fig. 1K, 1L and 1M, one or more extension portions 16a are adjustably attached to the main body 6 that is operably coupled to the sub-housing 16. The extension portions 16a can be extended or retracted to accommodate a packaging substrate.
According to an embodiment, the extension portions 16a can be extended or retracted horizontally, as in Fig. 1K, 1L, and 1M, to increase its overall reach and surface area, creating the extra space needed to hold and process a larger carton securely. In an example, the carton erector detects the size of the incoming carton. If the carton is larger than normal size, the device can manually be extended or automatically extends the extension portions 16a horizontally. The adjustment allows the carton erector to securely grip and support the carton along its larger dimensions without risking a misalignment or partial grip. In accordance with an implementation of the present disclosure, a flatly stacked two-dimensional carton is picked up or gripped by the main body 6 and the arm 16b of the pneumatic carton erector device. The description of the particular embodiment is illustrative and should not be construed as limiting the scope of the present disclosure.
According to another embodiment, the inverse gripper ports 12, as shown in Fig.1H- Fig.1K, may be required to grip or pick up the carton from a bunch of two-dimensionally folded cartons. The cartons are placed flat and may vary in size e.g., on the X & Y axis. The arm 16b along with the inverse gripper ports 12 is used to bend the carton at its crease to form the taped three-dimensional carton e.g., along Z axis. The pneumatic carton erector device is used to form a three-dimensional carton from the two-dimensional folded carton to be used for packaging and transporting different articles.
The carton erector device 100 includes a pneumatic system that uses compressed air to power and control the movements needed to form and assemble cartons. The inverse gripper ports 12 (as shown in Fig.1H -Fig 1K) may encompass elements such as a suction cup, foam, flat surface, or any mechanical structure capable of generating a reverse airflow or negative pressure to create suction for holding the two-dimensional carton. For example, the inverse gripper ports 12 enable holding on to the two-dimensional carton using suction that is created using the vacuum generator placed inside the main body 6. As depicted in Fig. 1M and 1N, the vacuum generator 48 requires compressed air to create suction, and the pneumatic and electrical circuitry is designed to create both vacuum or air blow-off or both through at least one inverse gripper ports 12. The pneumatic tube 38 (shown in Fig. IO supplies compressed air through the inlet 2. The compressed air is forced through narrow passages to create a pressure difference that results in suction. The vacuum generated is routed to multiple points, like suction cups in inverse gripper ports 12 both in main body 6 and sub-housing 16 (as shown in Fig.1H - Fig 1K), to lift and manipulate the cartons. Such an operation enables the main body 6 and the arm 16b to grip the two-dimensional carton or even push/release the three-dimensionally formed carton from the inverse gripper ports. The vacuum generator 48 holds and maintains the vacuum until the time to release the carton.
When air is expelled from the pneumatic system, the release of high-pressure air may be very loud. In an embodiment, the pneumatic carton erector device 100 includes at least one silencer 44 which is configured to reduce the noise level of the pneumatic carton erector device 100. The noise created by the pneumatic circuitry can be reduced by the silencer 44. The silencer 44 is made of porous material which works by dissipating this energy and reducing noise while allowing the air to escape. The silencer 44 is adapted to be accessed through the maintenance hatch 18 for example, during maintenance when the silencer has to be cleaned the maintenance hatch 18 may be screwed out or slid to access the silencer. Over time, silencers can become clogged with dust, debris, or oil particles from the compressed air leading to pressure drop in the pneumatic circuitry. The maintenance hatch allows for cleaning or replacement, ensuring the silencer remains effective in reducing noise.
Fig. 1L and 1M illustrate an actuator 8 that is adapted to be coupled with atleast one arm 16b. The arm 16b has one or more arm caps 36 that grips and opens up the flat carton. The arm finger 34 at the end of the extended portion folds, holds, and guides the carton flaps. The inverse gripper port 12 may be attached to arm finger 34 to provide additional grip while folding, holding, and guiding the carton flap.
The arms 16b swings either inwardly or outwardly rotationally to fold one or more pairs of flaps of the packaging substrate.
According to an embodiment, the extension portion 16a may include a locking mechanism 32 as illustrated in Fig. 1P to secure the position and orientation of the extension portions 16a with respect to the main body 6. After positioning the extension portion 16a at the required length and angle, the operator or the device engages the locking mechanism. The locking mechanism 32 secures the extension portion 16a in place by mechanically holding it, preventing it from sliding or rotating.
In another example, the inverse gripper port 12 is pneumatically closed such that there is no drop in compressed air pressure or vacuum and negates the need for externally connecting the inverse gripper ports to the vacuum generator or the compressed air inlet using tubes.
According to another embodiment of the present disclosure, the sub-housing 16 may include an input/output connector 2 that may be configured to receive power supply and I/O communication signals to/from robot/gantry/mechanical chain linkage.
Further, the change in orientation and position of main body 6 and arm 16b may vary at least in one of the X, Y, or Z axis in both positive and negative directions to grip cartons of various sizes. The change in orientation and position of the main body 6 and the arm 16b may be achieved with at least one rotational or prismatic joint 10 or a combination of the two types of joints. In case, the main body 6 and the arm 16b may be joined together using at least one rotational or prismatic joint 10 or a combination thereof, wherein the speed of the at least one rotational or prismatic joint 10, in respect of changing the orientation and position of the arm 16b, can be changed using a joint speed control 22 (shown in Fig. 1P).
The speed controller 22 is adapted to control manually or automatically the speed to extend/retract/rotate of the sub-housing (16). Furthermore, the rotational or prismatic joint or a combination of both, the main body 6 and the arm 16b form a closed system where vacuum is created along the joint eliminating the need for external tubing to facilitate pneumatic communication. The joints comprise pneumatically sealed joint members that prevents leakage during transfer of the vacuum from either internal or external vacuum generator through tubes, and the vacuum is transferred through the joints. Expressed differently, at least one of the joints between the main body 6 and the arm 16b are in pneumatic and electrical communication in a closed loop once the main body 6 and the arm 16b are joined.
In another implementation of the present disclosure, the change in orientation and position of main body 6 and the arm 16b may be accompanied with actuation of the extension portion 16a. For example, the main body 6, the arm 16b, and the extension portion 16a may be in pneumatic and electrical communication to form a closed loop in order to grip and form a three-dimensional taped carton. The operation in respect of change in orientation and position of main body 6, the arm 16b, and the extension portion 16a may be performed or controlled by the control units.
In another implementation of the present disclosure, the main body 6 and the arm 16b are controlled using an electrical control unit (ECU). The electrical control unit or ECU may be configured to operate the main body 6 and the arm 16b and/or the extension portion 16a interchangeably for gripping and forming the three-dimensional carton depending upon the desired size of the carton.
In an example, in order to form a carton of small size, the ECU may be configured to operate the inverse gripper ports of the main body 6 and the arm 16b to grip and form the carton. In another example, in order to form a carton of large size, the ECU may be configured to operate the inverse gripper ports of the main body 6, the arm 16b, along with the extension portion 16a to grip and form the carton. In another example, in order to form a carton of extra-large size, the ECU may be configured to operate the inverse gripper ports of the main body 6, the arm 16b, the extension portion 16a (as illustrated in Fig. 1D,1F,1L and 1M) along with the additional arm 16b and/or the extension portion 16a which may be additionally arranged on the third/fourth side surface of the main body to grip and form the carton.
In yet another implementation of the present disclosure, the inverse gripper ports and the arm may have internal check valves to cut off the vacuum in case the inverse gripper ports have leakage when picking up or gripping the carton. Additionally, either the main body or the arm may include at least one pneumatic inlet port, serving as the primary actuating medium in fluid communication. The fluid may include compressed air, hydraulic fluid, vacuum, and the like.
In yet another implementation of the present disclosure, the internal architecture of a portion of both the main body 6 and the sub-housing 16 may be designed to serve as the mechanical support structure while allowing ample internal space for the easy routing of all other components within the main body 6 and the sub-housing 16.
Further, a part of the main body 6, the extension portion 16a, and arm 16b may include at least one sensor. In an example, the at least one sensor may include a proximity sensor to detect the proximity between the device and the carton. The sensors may be a a joint motion sensor that may detect the extension 16a and/or the rotational angle of the arm 16b with respect to the main body 6. The at least one sensor may include a sensor that may track the fluid parameters such as compressed air, vacuum, hydraulic fluid and the like. At least one sensor may be a pressure sensor that may detect the pressure and/or suction created by the inverse gripper ports.
The device includes multiple sensors, that may be analog or digital, designed to monitor and provide real-time data on various operational parameters. These sensors detect the proximity of the packaging substrate, measure the flow rate and pressure of vacuum and compressed air, and verify the presence of vacuum in the inverse gripper ports 12. They also sense the presence, dimensions, position, and orientation of the packaging substrate to ensure proper handling. Additionally, the sensors track the position and state of the sub-housing 16, including its arms, fingers, and extensions, as well as monitor environmental conditions such as temperature and humidity. They further assess the effectiveness of silencers and filters, ensuring optimal system performance and maintenance.
According to an embodiment of the present disclosure, the sub-housing 16 has been designed to be modularly attached to the main body 6 on any of the side surfaces through at least one rotational or prismatic joint or both. The main body 6 and the sub-housing 16 are designed to accommodate the rotational and/or prismatic joint. The joints are configured to allow the extension or retraction or rotation hold or release a packaging substrate.
Further, the main body 6 and the sub-housing 16 have at least one inverse gripper port arranged at the bottom surface of the main body 6 and/or sub-housing 16 that enables gripping onto the carton using a suction, which is created using a vacuum generator. The vacuum generator is either placed inside the main body 6 or taken from an external supply. The inverse gripper ports can be either suction cups, foam boards, or a combination of mechanical architecture that creates a negative pressure when the surface of the carton touches the inverse gripper ports.
Furthermore, the inverse gripper ports arranged on the bottom surface of the main body may possess a modular mechanical design, allowing it to adjust its position and orientation relative to the main body along X, Y, and Z direction e.g., X, Y, Z axis. The change in position and/or orientation is done either manually or automatically through the control unit using at least a rotational or prismatic joint or a combination of both. The inverse gripper ports are pneumatically closed such that there is no drop in compressed air pressure or vacuum and negates the need for externally connecting the inverse gripper ports to the main body or the arm using tubes.
Furthermore, the mechanical architecture of the main body 6 and the sub-housing 16 is designed to be able to accommodate the pneumatic and the electrical circuitry and other support structures and components can be routed through the device easily both from manufacturing, troubleshooting, and servicing of the pneumatic carton erector device 100.
In another implementation of the present disclosure, the pneumatic carton erector device 100 may include at least one control unit that is configured to communicate with a robot/gantry/mechanical chain linkage, via I/O Connector 2, to control the operation of the pneumatic carton erector device 100. The modular coupler 14 is configured to secure the robotic attachment and detachment of tools or accessories on a robotic arm or other automated systems to the robot mounting face 13. The modular coupler 14 may be compatible with one or more end of arm flanges of different robot/gantry/mechanical chain linkage to enable the pneumatic carton erector device 100 to be coupled with.
As depicted in Fig. 1O, the I/O cable 40 transmits control signals and feedback between the robotic arm and the carton erector device. According to an embodiment, the control signals from robot/gantry/mechanical chain linkage are received by the ECU through the I/O cable. In a scenario, once the carton erector device 100 has formed a carton, the ECU sends a signal through the I/O cable to notify the robot/gantry/mechanical chain linkage that the carton is ready for pickup. In another scenario, the robot/gantry/mechanical chain linkage can signal the carton erector device 100 to begin forming the next carton once it completes the current cycle.
In a different scenario, the I/O cable 40 provides real-time feedback from the pneumatic carton erector device, such as whether a carton is jammed, misaligned, or if there’s an issue with the pneumatic system. If any error occurs, the robot/gantry/mechanical chain linkage can pause its operation until the issue is resolved, ensuring smooth and safe operation for both machines.
The robot/gantry/mechanical chain linkage is connected by means of modular coupler 14 arranged at the top of the main body 6. In an example, the operation associated with the pneumatic control valves includes, but is not limited to, the creation of the vacuum which is configured to grip the carton or performing air-blow off which is configured to release the carton.
Further, the control unit may be adapted to change the position and orientation of the main body 6and the sub-housing 16 in respect of each other. Furthermore, the control unit may be adapted to control the position and the orientation of the inverse gripper ports 12 of the main body 6. In an implementation, the inverse gripper port may include a built-in sensor to provide feedback on the suction state, carton proximity, and carton presence. The in-built sensor may be used to provide feedback to the control unit for controlling the operations of the pneumatic carton erector device 100.
In another implementation of the present disclosure, the inverse gripper ports 12 may be in pneumatic communication with at least one pneumatic check valve to cut off the vacuum or air blow-off in the pneumatic circuitry in case there are leaks in at least one of the inverse gripper ports.
In another implementation of the present disclosure, to accommodate the ability to flip or mirror the arm 16b while being connected with the main body 6, the architecture of both the main body 6 and the arm 16b are designed to have at least one fastening provision and/or interlocking location to avoid collision with the corresponding main body and the arm 16b.
In an example, the main body and/or the arm 16b may include a locking means that prevent a collision between each other. In another example, the main body and/or the arm may include a locking means that prevents change in orientation and position of the arm beyond a predetermined angle. Further, the pneumatic and the electrical circuitry are designed to be routed within the joints between the main body and the arm by eliminating the need for additional tubing or wiring.
Fig.1U illustrate exemplary embodiments of the packaging substrate erector and flattener device 100 with extension portion in extended position. However, the embodiments are only for illustrative purposes and should not restrict the scope of the invention.
In an implementation of the present disclosure, at least a part of the main body and the arm is manufactured using metals, polymers, nonmetallic materials, traditional manufacturing techniques, new manufacturing techniques, and the like. The metals include, but are not limited to, Aluminum, Steel, and Titanium. The polymers may include, but are not limited to, Carbon Fibre, Nylon, ABS, PLA, and the like. The non-metallic materials may include, but are not limited to, carbon, phosphorus, and the like. The traditional manufacturing techniques may include, but are not limited to, casting, molding, machining, welding, extrusion, and the like. The new manufacturing techniques may include, but are not limited to, additive manufacturing, sintering, stereolithography, or any combination thereof.
Further, the pneumatic carton erector device may include a plurality of modular sections that can be joined together and controlled either manually or automatically using at least one control unit. The multiple modular sections, through adjustments in size, position, and orientation of the main body, the arm, the extension portion, and/or the inverse gripper ports enable the production or shaping of cartons in a wide range of sizes and configurations.
According to an embodiment of the present disclosure, an assembly of cams 50 in Fig.1X or mechanical assembly is arranged near the robot/gantry/mechanical arm to enable folding of the flaps at the top or bottom of the carton and enable taping of the carton flaps. The cam 50 assembly is designed to assist in folding the flaps of the carton at either the top or bottom. Fig.1T shows an exemplary embodiment of the packaging substrate erector and flattener device illustrating arm movement in the upward direction. The upward movement of the arm aids in moving the flap in an upward direction.
These set of cams 50 can be controlled either manually or automatically to change the position and orientation. This control is in tandem with the control system of the carton erector. This change of position and orientation of the cams is done to accommodate the variations in the size, shape, and other parameters of the cartons such as thickness, flute and so on.
FIG.1Q illustrates a front view of packaging substrate erector and flattener device illustrating opening of arm cap 36 for adjusting its position. The arm finger 34 can be removed or changed by opening the arm cap 36 and moving the arm finger 34. The arm finger 34 can be positioned in a different position as illustrated in FIG.1R. The position of the arm finger 34 may be swapped with the arm cap 36 to enable case packaging substrate folding in both directions. This enables the packaging device to fold the substrate in either direction, accommodating various packaging requirements. For instance, it may be folded towards the left or right side or folded from the top or bottom, depending on the packaging workflow. (Fig 1Ya & 1Yb). When the taping head 52 applies tape to the bottom of the packaging substrate, it is critical to avoid collisions with the arm finger 34. By swapping the arm finger 34 and arm cap 36, the device ensures that the arm finger 34 is positioned away from the taping head’s 52 path, preventing interference during the taping process. As illustrated in Fig. 1R, the arm 16b of the packaging substrate erector and flattener device another position in the main body, in accordance with various embodiments of the present disclosure.
According to an embodiment, the suction cup can be detachably attached to the main body 6 and/or arm 16b and/or extension 16a. FIG.1S illustrates a perspective exploded view of packaging substrate erector and flattener device illustrating removal of suction cup with tools such as an Allen key.
The present invention also provides a method of manufacturing or forming a three-dimensional carton from a two-dimensional carton using the integrated pneumatic carton erector device, as illustrated in Fig 1Z. At a step 202, the method of erecting a packaging substrate includes sensing the presence, proximity and dimensions of a packaging substrate by one or more sensors. In an embodiment, sensing or detecting the proximity of the cartons may be carried out by laser aligners 28. The sensors then measure the reflected light to calculate the distance and dimensions of the carton.
At a step 204, the sensed distance and dimensions and/or other parameters are sent to the control unit or ECU.
At a step 206, the ECU receives the sensed parameters such as distance, dimension etc. of the carton and provides control signals based on the sensed parameters to the extension portion 16a to extend/retract the extension portion 16a based on the dimensions of the carton. As an illustration, a larger carton with larger dimensions in the horizontal direction may require extension of the extension portion 16a.
At a step 208, the extension portion 16a can be either extended or retracted to fit a packaging substrate, based on the control signals received. At a step 210, the control signals are provided by a control unit to adjust the positioning and orientation of the one or more arms 16b to accommodate the carton. At a step 212, the arms 16b extend or retract and/or rotate based on the received control signals to enable the arm to fold inwardly one or more pairs of flaps of the packaging substrate. This is to enable the arms 16b to fold inwardly one or more pairs of flaps of the packaging material.
At a step 214, the suction state of inverse gripper ports or inverse gripper ports 12 may be sensed or monitored by the sensors. The inverse gripper ports 12 with suction cups hold the packaging material or with a secure grip. The sensors help verify that the suction is properly engaged to avoid errors in handling.
At a step 216, the sensed suction state is sent to the control unit. At a step 218, control signals are provided by a control unit based on the sensed suction state to the pneumatic control unit to lift and retain the packaging substrate. The feedback provides information to the control unit about whether the suction ports properly grip the packaging substrate, which is critical for ensuring secure handling.
At a step 220, the pneumatic control unit enables the vacuum in the inverse gripper ports using the internal or external vacuum generator.
At a step 222, the device 100 lifts the carton with inverse gripper ports 12.
At a step 223, the device confirms the presence of carton by sensor. At a step 224, the device 100 folds the flaps of the carton inwardly.At a step 226, the sensor validates the device arm position. At a step 228, the folded carton is pushed into the cam mechanism to tape the bottom of the carton. At a step 230, the sensors will validate the taping and the folding of the carton. At a step 232, the erected packaging substrate or carton moves to the next phase for further processing, filling, or packaging.
The present disclosure offers numerous advantages in forming a plurality of cartons of various shapes and sizes. The present invention helps in meeting the requirement of the packaging industry by allowing efficient manufacturing/forming of customized cartons of different sizes.
Further, the present disclosure provides a pneumatic carton erector device capable of accommodating cartons of various dimensions, delivering significant advantages in versatility and efficiency. By allowing adjustments to handle different carton sizes, the device eliminates the need for multiple machines.
Further, the present disclosure provides an efficient pneumatic erector that is light in weight, easy to install, flexible and aesthetic in nature, low in cost, and the like.
Further, the integration of laser aligners and sensors ensures precise alignment and detection of carton dimensions, allows for precise adjustments to accommodate cartons of various sizes without manual intervention.
Furthermore, integration of robot/gantry/mechanical chain linkage enhances efficiency by automating the handling and positioning of cartons, reducing downtime and improving throughput. The use of robot/gantry/mechanical chain linkage and laser sensors allows for easy integration into larger automated systems, such as fully automated packaging lines.
While the present invention has been described with reference to certain preferred embodiments and examples thereof, other embodiments, equivalents, and modifications are possible and are also encompassed by the scope of the present invention.
,CLAIMS:WE CLAIM
1. A packaging substrate erector and flattener device (100), comprising:
a main body (6) comprising one or more control units;
one or more sub-housing (16), coupled to the main body (6), attached to the main body (6) by prismatic or rotational joints adapted to extend/retract/rotate to aid in forming, de-forming, holding, lifting, retaining, or releasing a packaging substrate of varying dimensions wherein the one or more sub-housing (16) is attached to one or more sides of the main body (6);
one or more inverse gripper ports (12) with or without a built-in filter attached to the main body (6) and the sub-housing (16), wherein the one or more inverse gripper ports (12) is configured to hold and release a packaging substrate;
one or more parts of the main body (6) and/or the sub-housing (16) are manufactured by conventional manufacturing processes and/or using additive manufacturing processes.
at least one pneumatic circuitry adapted to fluidly connect the main body (6) and/or sub-housing (16), one or more inlet (4), one or more pneumatic control units, one or more vacuum generator (48), and/or one or more inverse gripper ports (12) and/or one or more actuators and/or other sub-components, is made with either conventional tubes and pneumatic fittings and/or using additive manufacturing and/or combination of both.
one or more control units;
one or more I/O Connector (2)
a robot/gantry/mechanical chain linkage mounting face (13).
wherein the main body (6) includes at least one Human-Machine-Interface (3) present to communicate the current state and/or errors in the device (100)

2. The device (100), as claimed in claim 1, wherein the main body (6) further comprises:
at least one inlet (4) with or without a built-in filter and/or check valve configured to receive compressed air;
at least one pneumatic control unit receives the compressed air from the inlet (4);
at least one control valve within the pneumatic control unit is configured to release/hold compressed air through the pneumatic circuit to other actuators or sub-components;
at least one internal vacuum generator fluidly connected to at least one inverse gripper ports (12), and at least one compressed air input from the pneumatic control unit is fluidly connected to the vacuum generator adapted to generate vacuum to enable suction in at least one inverse gripper port (12) through with or without check valves.

at least one internal built-in filter fluidly connected to the vacuum generator (48) and/or to one or more inverse gripper ports (12) present in both the main body (6) and sub-housing (16).

3. The device (100), as claimed in claim 1, wherein the main body (6) further comprises:
at least one inlet (4) with or without a built-in filter and/or check valve configured to receive vacuum flow;
at least one pneumatic control unit receives this vacuum flow from the inlet;
at least one control valve within the pneumatic control unit is configured to release/hold vacuum through the pneumatic circuit to other actuators and/or at least one inverse gripper port (12).
at least one vacuum circuitry comprising at least one air blow-off port, which is fluidly connected to the pneumatic control unit, to enable quick release of the packaging substrate from the inverse gripper ports (12) through with or without check valves.

4. The device (100), as claimed in claim 1, wherein comprises one or more control units that are part of either the main body (6) or can be added to the sub-housing (16) wherein the control units include:
a pneumatic control unit, wherein the pneumatic control unit is configured to control the flow, pressure, and direction of the compressed air or vacuum in the pneumatic control circuitry through the control valves and/or other pneumatic components manually or automatically based on the signals received from/to an electrical control unit;
wherein the electrical control unit is configured to act either as a master or a salve to send/receive signals to or from a robot/gantry/mechanical chain linkage controller and/or the Human-Machine-Interface(HMI) (3) to actuate the device (100).
5. The device (100), as claimed in claim 1, wherein one or more sub-housing (16) comprises one or more extension portions (16a) attached to the main body (6) by prismatic or rotational joints or both,
wherein the joints are fluidly connected directly with either the internal or external vacuum generator through tubes and/or the vacuum is transferred through the joints using pneumatically sealed joint members wherein the joints are configured to extend/retract/rotate to hold/release a packaging substrate.

6. The device (100), as claimed in claim 1, wherein the one or more sub-housing (16) comprising one or more arms (16b) configured to swing rotationally to fold either inwardly or outwardly one or more pairs of flaps of the packaging substrate attached to the main body (6) by prismatic or rotational joints,
wherein the joints transfer vacuum from the internal or external vacuum generator through tubes and/or pneumatically sealed joint members that are adapted to prevent leakage of vacuum to the at least one or more arms (16b), wherein the one or more arms (16b) comprise:
an arm cap (36) and
an arm finger (34) attached at one or more positions to the arm (16b).
wherein the position of the arm finger (34) is adapted to be swapped with the arm cap (36) to enable case packaging substrate forming flow in left-to-right and/or right-to-left directions, wherein the taping head (52) tapes the bottom of the packaging substrate, without colliding with the arm finger (34).
an inverse gripper port (12) that is part of the arm finger that helps hold the side face of the packaging substrate and fold it from a flat state to an open cuboid state or vice versa.

7. The device (100), as claimed in claim 1, wherein the main body (6) comprises one or more laser aligners (28) that are configured to aid the packaging substrate erector device to align manually or automatically to the folding line of the packaging substrate along the axial line of the rotational joint of the arm (16b).

8. The device (100), as claimed in claim 1, wherein the device (100) comprises one or more sensors that are configured to sense the proximity of a packaging substrate, flow rate of vacuum and compressed air, pressure of vacuum and compressed air, presence of vacuum in the one or more inverse gripper ports (12), presence of a packaging substrate, position and orientation of the sub-housing (16), the current state of the sub-housing arms, fingers, and extension, temperature and humidity, the current state of silencer and filter effectiveness and the dimension of the packaging substrate.

9. The device (100), as claimed in claim 1, wherein at least one or more HMI is present in the main body (6), is in electrical communication with the electrical control unit and configured to measure the operational parameters of the device (100) along with the sensors connected to it and send the operational parameters to the HMI to enable better communication of the past and/or current state and/or errors and/or next steps of the device (100).

10. The device (100), as claimed in claim 2, wherein the vacuum is created in one or more inverse gripper ports (12) by one or more internal vacuum generators and/or one or more external vacuum generators.

11. The device (100), as claimed in claim 1, wherein the main body (6) has at least one speed controller (22) that is adapted to control manually or automatically the speed to extend/retract/rotate of the sub-housing (16).

12. The device (100), as claimed in claim 1, the robot mounting face (13) in the main body (6) adapted to be operably coupled to the end of the robot/gantry/mechanical chain linkage (30) wherein the coupling can be done directly to the packaging substrate erector device or using a modular coupler (14) in between.

13. The device (100), as claimed in claim 1, wherein the main housing (6) comprises at least one silencer (44), which is part of the vacuum and/or pneumatic circuitry to reduce the noise level of the device (100).

14. The device (100), as claimed in claim 1, wherein each of the one or more inverse gripper ports (12) comprises either a fixed or an adjustably mounted vacuum cup adapted to hold the packaging substrate at varying positions and/or orientations.

15. The device (100), as claimed in claim 1, wherein the main body(6) comprises at least a locking mechanism (32) to secure, manually or automatically, the position and orientation of the sub-housing (16) with respect to the main body (6).

16. A method (200) of erecting/flattening a packaging substrate, comprises:
sensing (202) manually and/or automatically the presence, proximity and dimensions of a packaging substrate by one or more sensors and one or more laser aligners (28);
sending (204) sensed packaging substrate parameters to the one or more control units;
providing (206) control signals by at least one control unit to at least one extension portion (16) to extend/retract the extension portion (16);
adjusting (208) the at least one extension portion (16) by extending/retracting extension portion (16) manually and/or automatically to accommodate a packaging substrate;
providing (210) control signals by a control unit to adjust the positioning and orientation of the device (100) to align with the packaging substrate;
adjusting (212) the at least one of the one or more arms (16b) by extending or retracting or rotating to enable the arm to fold inwardly or outwardly one or more pairs of flaps of the packaging substrate;
sensing (214) the suction state or working condition of one or more inverse gripper ports (12) by one or more sensors;
sending (216) sensed suction state to the control unit;
providing (218) control signals by at least one control unit based on the sensed suction state to provide vacuum to at least one inverse gripper port (12) to lift and retain the packaging substrate;
lifting (222) the carton and confirming its presence using the sensors;
confirming (223) the presence of carton by sensor;
folding (224) the flaps of the carton inwardly;
validating (226) the device arm position by the sensor;
pushing (228) the folded carton into the cam mechanism to tape the bottom of the carton;
validating (230) the taping and the folding of the carton by the sensor; and
transporting (232) the erected packaging substrate or carton moves to the next phase for further processing, filling, or packaging,

wherein sensing (202) further includes providing the sensor feedback to at least one or more control units to communicate the current state of the device (100) during the process of erecting/flattening a packaging substrate.