Description:FIELD OF INVENTION
[0001] Embodiments of the present disclosure relate to the field of industrial packaging systems, and more particularly, an automated machine for forming a corrugated case and a method thereof.
BACKGROUND
[0002] In industrial packaging systems, corrugated cases are widely used for product packaging and transportation. To optimize space and handling, the corrugated cases are supplied in a flat condition by manufacturers and must be fully formed and sealed before product filling. Traditionally, manual or semi-automated processes have been employed for erecting and sealing corrugated cases. However, conventional methods often lead to inconsistencies in case formation, increased labor costs, and slower production speeds.
[0003] Furthermore, traditional case erectors typically operate in multiple sequential stages, requiring the flat corrugated case to move across different processing stations. This multi-stage approach increases processing time and machine footprint, leading to inefficient space utilization, particularly in high-production environments where multiple processing stations demand additional floor space.
[0004] Hence, there is a need for an automated machine for forming a corrugated case and a method thereof which addresses the aforementioned issue(s).
OBJECTIVES OF THE INVENTION
[0005] Primary objective of the invention is to provide an automated machine for erecting and sealing a flat corrugated cases with an integrated taping assembly, minor flap closing assembly, and major flap closing assembly in a single station.
[0006] Another objective of the invention is to incorporate a movable taping assembly with articulated mechanical arms for enabling efficient sealing and automated box transfer, reducing processing time and machine footprint.
[0007] Yet another objective of the invention is to incorporate a Human-Machine Interface (HMI) to enhance user control and monitoring.
BRIEF DESCRIPTION
[0008] In accordance with an embodiment of the present disclosure, an automated machine for forming a corrugated case is provided. The automated machine includes an in-feeder assembly adapted to supply a flat corrugated case for opening, erecting, and sealing within a controlled environment. The automated machine includes at least four suction cups arranged on a vertical frame. The at least four suction cups are adapted to attach to one side of the flat corrugated case. The at least four suction cups are adapted to expand the flat corrugated case into a box shape thereby transforming the flat corrugated case into an erected corrugated case. The at least four suction cups are adapted to hold the erected corrugated case in position for processing. The automated machine includes a minor flap closing assembly including at least two pneumatically operated arms adapted to engage and close a plurality of minor flaps of the erected corrugated case. The automated machine includes a major flap closing assembly including a platform. The platform includes at least two pneumatically operated rods adapted to engage and fold a plurality of major flaps of the erected corrugated case after the plurality of minor flaps are closed. The automated machine includes a taping assembly including a horizontal platform placed on a sliding rail. The horizontal platform is adapted to move along the sliding rail in a back-and-forth direction to facilitate sealing of the erected corrugated case. The taping assembly includes at least two articulated mechanical arms. A first articulated mechanical arm is adapted to apply a sealing tape to a bottom flap of the erected corrugated case while the horizontal platform moves forward horizontally. A second articulated mechanical arm is adapted to push the sealed erected corrugated case out to a delivery station as the horizontal platform moves backward. The taping assembly, the minor flap closing assembly, and the major flap closing assembly are all integrated into a single machine station. The automated machine includes a human-machine interface adapted to control a plurality of machine operations.
[0009] In accordance with another embodiment of the present disclosure, a method to operate an automated machine for forming a corrugated case is provided. The method includes supplying, by an in-feeder assembly, a flat corrugated case for opening, erecting, and sealing within a controlled environment. The method includes attaching, by at least four suction cups, to one side of the flat corrugated case. The method includes expanding, by the at least four suction cups, the flat corrugated case into a box shape thereby transforming the flat corrugated case into an erected corrugated case. The method includes holding, by the at least four suction cups the erected corrugated case in position for processing. The method includes engaging and closing, by at least two pneumatically operated arms of a minor flap closing assembly, a plurality of minor flaps of the erected corrugated case. The method includes engaging and folding, by at least two pneumatically operated rods of a platform of a major flap assembly, a plurality of major flaps of the erected corrugated case after the plurality of minor flaps are closed. The method includes moving, by a horizontal platform of a taping assembly, along the sliding rail in a back-and-forth direction to facilitate sealing of the erected corrugated case. The method includes applying, by a first articulated mechanical arm of at least two articulated mechanical arms, a sealing tape to a bottom flap of the erected corrugated case while the horizontal platform moves forward horizontally. The method includes pushing, by a second articulated mechanical arm of the at least two articulated mechanical arms, the sealed erected corrugated case out to a delivery station as the horizontal platform moves backward. The taping assembly, the minor flap closing assembly, and the major flap closing assembly are all integrated into a single machine station. The method includes controlling, by a human-machine interface, a plurality of machine operations.
[0010] To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:
[0012] FIG. 1 is a schematic representation of an automated machine for forming a corrugated case in accordance with an embodiment of the present disclosure; and
[0013] FIG. 2(a) illustrates a flow chart representing the steps involved in a method to operate an automated machine for forming a corrugated case in accordance with an embodiment of the present disclosure; and
[0014] FIG. 2(b) illustrates continued steps of the method of FIG. 2(a) in accordance with an embodiment of the present disclosure.
[0015] Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.
DETAILED DESCRIPTION
[0016] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.
[0017] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or subsystems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
[0018] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
[0019] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
[0020] In accordance with an embodiment of the present disclosure, an automated machine for forming a corrugated case is provided. The automated machine includes an in-feeder assembly adapted to supply a flat corrugated case for opening, erecting, and sealing within a controlled environment. The automated machine includes at least four suction cups arranged on a vertical frame. The at least four suction cups are adapted to attach to one side of the flat corrugated case. The at least four suction cups are adapted to expand the flat corrugated case into a box shape thereby transforming the flat corrugated case into an erected corrugated case. The at least four suction cups are adapted to hold the erected corrugated case in position for processing. The automated machine includes a minor flap closing assembly including at least two pneumatically operated arms adapted to engage and close a plurality of minor flaps of the erected corrugated case. The automated machine includes a major flap closing assembly including a platform. The platform includes at least two pneumatically operated rods adapted to engage and fold a plurality of major flaps of the erected corrugated case after the plurality of minor flaps are closed. The automated machine includes a taping assembly including a horizontal platform placed on a sliding rail. The horizontal platform is adapted to move along the sliding rail in a back-and-forth direction to facilitate sealing of the erected corrugated case. The taping assembly includes at least two articulated mechanical arms. A first articulated mechanical arm is adapted to apply a sealing tape to a bottom flap of the erected corrugated case while the horizontal platform moves forward horizontally. A second articulated mechanical arm is adapted to push the sealed erected corrugated case out to a delivery station as the horizontal platform moves backward. The taping assembly, the minor flap closing assembly, and the major flap closing assembly are all integrated into a single machine station. The automated machine includes a human-machine interface adapted to control a plurality of machine operations.
[0021] FIG. 1 is a schematic representation of an automated machine (100) for forming a corrugated case in accordance with an embodiment of the present disclosure. The automated machine (100) includes an in-feeder assembly (105) adapted to supply a flat corrugated case for opening, erecting, and sealing within a controlled environment. The flat corrugated case are corrugated cases, typically shipped in a flat, unassembled state from manufacturers to optimize storage and transportation. The controlled environment ensures a systematically operated and customizable sequence of movements for the flat corrugated case, allowing an operator to adjust the opening, erecting, and sealing processes through a user interface based on the case dimensions.
[0022] It must be noted that the user interface utilized for process control is a Human-machine interface (130) (HMI).
[0023] The automated machine (100) includes at least four suction cups arranged on a vertical frame. The at least four suction cups are adapted to attach to one side of the flat corrugated case. The at least four suction cups are adapted to expand the flat corrugated case into a box shape thereby transforming the flat corrugated case into an erected corrugated case. The at least four suction cups are adapted to hold the erected corrugated case in position for processing.
[0024] It must be noted that, the automated machine (100) further includes a servo motor is positioned at a top portion of the machine (100) to ensure precise positioning, accurate programming, and enhanced operational flexibility.
[0025] In one embodiment, the position of the at least four suction cups is adjustable based on the size of the flat corrugated case, allowing the at least four suction cups to attach to the case in the most appropriate position for effective opening and erecting. The movement and operation of the suction cups are controlled by the servo motor (170), ensuring smooth and precise execution.
[0026] The automated machine (100) includes a minor flap closing assembly (115) including at least two pneumatically operated arms (145a, 145b) adapted to engage and close a plurality of minor flaps of the erected corrugated case.
[0027] The automated machine (100) includes a major flap closing assembly (120) including a platform (150). The platform (150) includes at least two pneumatically operated rods (155) adapted to engage and fold a plurality of major flaps of the erected corrugated case after the plurality of minor flaps are closed.
[0028] It must be noted that the minor flap closing assembly (115) and the major flap closing assembly (120) are positioned at a lower section of the automated machine (100), strategically arranged to ensure efficient flap closure. The at least two pneumatically operated arms (145a, 145b) and the at least two pneumatically operated rods (155) operate using pneumatic mechanisms, which provide consistent force and controlled motion to securely fold and close the flaps without damaging the case.
[0029] The erected corrugated case is formed at an exact 90-degree angle through a coordinated operation of the at least four suction cups, the minor flap closing assembly (115), and the major flap closing assembly (120).
[0030] The automated machine (100) includes a taping assembly (125) including a horizontal platform (160) placed on a sliding rail. The horizontal platform (160) is adapted to move along the sliding rail in a back-and-forth direction to facilitate sealing of the erected corrugated case. The taping assembly (125) includes at least two articulated mechanical arms (165a, 165b). A first articulated mechanical arm (165a) is adapted to apply a sealing tape to a bottom flap of the erected corrugated case while the horizontal platform (160) moves forward horizontally.
[0031] It must be noted that the horizontal platform (160) utilizes a cylinder-based antifriction roller mechanism, allowing it to smoothly roll beneath the erected corrugated case during the taping process. Initially, a leading edge of the sealing tape adheres to the erected corrugated case, followed by the application of sealing tape along its surface, and finally, a tail edge is secured to complete the sealing.
[0032] In another embodiment, the taping assembly (125) is adapted to move on a pneumatic linear actuator.
[0033] In an embodiment, the sealing tape is Biaxially Oriented Polypropylene tape applied to seal the bottom flaps of the erected corrugated case.
[0034] Examples for other the sealing tape includes but is not limited to pressure-sensitive polypropylene tape, hot melt sealing, reinforced filament tape, and the like.
[0035] Additionally, a second articulated mechanical arm (165b) is adapted to push the sealed erected corrugated case out to a delivery station as the horizontal platform (160) moves backward.
[0036] Further, the tapping assembly includes a mechanical sensor adapted to detect the completion of the taping process. The mechanical sensor detects when the sealing tape exits the sealed erected corrugated case, triggering a cutting mechanism to sever the sealing tape at the appropriate position.
[0037] The taping assembly (125), the minor flap closing assembly (115), and the major flap closing assembly (120) are all integrated into a single machine station.
[0038] The automated machine (100) includes the human-machine interface (130) adapted to control a plurality of machine operations. The human machine interface is a technology that allows people to interact with machines. HMIs are used in many applications, including but are not limited to industrial automation, oil and gas, air conditioning, and the like. Examples of HMIs includes but not limited to touchscreens, keyboards, voice control, gesture recognition, haptics, and the like. The human-machine interface (130) is a programmable logic controller-based system. The human-machine interface (130) is adapted to store and display real-time data and historical data of the automated machine (100). The real-time data and the historical data includes product information, stock-keeping unit tracking, production counts over defined time intervals, sealing tape consumption, machine operating time, machine downtime, and diagnostic reports for performance analysis and maintenance planning.
[0039] In an embodiment, the automated machine (100) is operated at maximum output speed of six cases per minute. The output speed may be set as per industrial requirements and the operator's skill level to ensure optimal performance.
[0040] Let’s consider an example, a company “X” uses the automated machine (100) to form the corrugated cases for filling with their products. The company “X” receives flat corrugated cases from the manufacturer in their original form to save storage space. The in-feeder assembly (105) of the automated machine (100) supplies the flat corrugated cases in a sequential manner. Once the flat corrugated case reaches the at least four suction cups, the at least four suction cups attach to the case and expand it into a box shape. The minor flap closing assembly (115) and the major flap closing assembly (120) then engage to securely close the flaps, preparing the case for sealing. The taping assembly (125), moving along the sliding rail, applies sealing tape to the bottom flap. Finally, a mechanical sensor detects the tape’s position and triggers the cutting mechanism to complete the process before the sealed box is pushed to the delivery station for further processing.
[0041] FIG. 2(a) illustrates a flow chart representing the steps involved in a method (200) to operate an automated machine for forming a corrugated case in accordance with an embodiment of the present disclosure. FIG. 2(b) illustrates continued steps of the method (200) of FIG. 2(a) in accordance with an embodiment of the present disclosure. The method (200) includes supplying, by an in-feeder assembly, a flat corrugated case for opening, erecting, and sealing within a controlled environment in step 205. Corrugated cases are typically shipped in a flat, unassembled state from manufacturers to optimize storage and transportation. The controlled environment ensures a systematically operated and customizable sequence of movements for the flat corrugated case, allowing an operator to adjust the opening, erecting, and sealing processes through a user interface based on the case dimensions.
[0042] It must be noted that the user interface utilized for process control is a Human-Machine Interface (HMI).
[0043] The method (200) includes attaching, by at least four suction cups, to one side of the flat corrugated case in step 210.
[0044] The method (200) includes expanding, by the at least four suction cups, the flat corrugated case into a box shape thereby transforming the flat corrugated case into an erected corrugated case in step 215.
[0045] The method (200) includes holding, by the at least four suction cups the erected corrugated case in position for processing in step 220. It must be noted that, the automated machine further includes a servo motor is positioned at a top portion of the machine to ensure precise positioning, accurate programming, and enhanced operational flexibility.
[0046] In one embodiment, the position of the at least four suction cups is adjustable based on the size of the flat corrugated case, allowing the at least four suction cups to attach to the case in the most appropriate position for effective opening and erecting. The movement and operation of the suction cups are controlled by the servo motor, ensuring smooth and precise execution.
[0047] The method (200) includes engaging and closing, by at least two pneumatically operated arms of a minor flap closing assembly, a plurality of minor flaps of the erected corrugated case in step 225.
[0048] The method (200) includes engaging and folding, by at least two pneumatically operated rods of a platform of a major flap assembly, a plurality of major flaps of the erected corrugated case after the plurality of minor flaps are closed in step 230. The at least two pneumatically operated arms and the at least two pneumatically operated rods operate using pneumatic mechanisms, which provide consistent force and controlled motion to securely fold and close the flaps without damaging the case.
[0049] The method (200) includes moving, by a horizontal platform of a taping assembly, along the sliding rail in a back-and-forth direction to facilitate sealing of the erected corrugated case in step 235.
[0050] The method (200) includes applying, by a first articulated mechanical arm of at least two articulated mechanical arms, a sealing tape to a bottom flap of the erected corrugated case while the horizontal platform moves forward horizontally in step 240.
[0051] It must be noted that the horizontal platform utilizes a cylinder-based antifriction roller mechanism, allowing it to smoothly roll beneath the erected corrugated case during the taping process. Initially, a leading edge of the sealing tape adheres to the erected corrugated case, followed by the application of sealing tape along its surface, and finally, a tail edge is secured to complete the sealing.
[0052] In another embodiment, the taping assembly is adapted to move on a pneumatic linear actuator.
[0053] In an embodiment, the sealing tape is Biaxially Oriented Polypropylene tape applied to seal the bottom flaps of the erected corrugated case.
[0054] The method (200) includes pushing, by a second articulated mechanical arm of the at least two articulated mechanical arms, the sealed erected corrugated case out to a delivery station as the horizontal platform moves backward. The taping assembly, the minor flap closing assembly, and the major flap closing assembly are all integrated into a single machine station in step 245.
[0055] The method (200) includes controlling, by a human-machine interface, a plurality of machine operations in step 250. The human-machine interface is a programmable logic controller-based system. The human-machine interface is adapted to store and display real-time data and historical data of the automated machine. The real-time data and the historical data include product information, stock-keeping unit tracking, production counts over defined time intervals, sealing tape consumption, machine operating time, machine downtime, and diagnostic reports for performance analysis and maintenance planning.
[0056] Various embodiments of the automated machine (100) for forming a corrugated case and the method thereof as described above provide several advantages. One such advantage is the reduction of manual labor while improving production speed. Furthermore, the automated machine integrates multiple functions, including opening, erecting, flap closing, and sealing, into a single station, thereby reducing the machine footprint and optimizing floor space utilization. Additionally, the automated machine minimizes movement between stations, resulting in faster case formation and sealing.
[0057] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof.
[0058] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.
[0059] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.
, Claims:1. An automated machine (100) for forming a corrugated case, comprising:
an in-feeder assembly (105) adapted to supply a flat corrugated case for opening, erecting, and sealing within a controlled environment;
at least four suction cups (110) arranged on a vertical frame, wherein the at least four suction cups are adapted to:
attach to one side of the flat corrugated case;
expand the flat corrugated case into a box shape thereby transforming the flat corrugated case into an erected corrugated case; and
hold the erected corrugated case in position for processing;
a minor flap closing assembly (115) comprising at least two pneumatically operated arms (145a, 145b) adapted to engage and close a plurality of minor flaps of the erected corrugated case;
a major flap closing assembly (120) comprising a platform (150), wherein the platform (150) comprises at least two pneumatically operated rods (155) adapted to engage and fold a plurality of major flaps of the erected corrugated case after the plurality of minor flaps are closed;
a taping assembly (125) comprising:
a horizontal platform (160) placed on a sliding rail, wherein the horizontal platform (160) is adapted to move along the sliding rail in a back-and-forth direction to facilitate sealing of the erected corrugated case;
at least two articulated mechanical arms (165a, 165b), wherein a first articulated mechanical arm (165a) is adapted to apply a sealing tape to a bottom flap of the erected corrugated case while the horizontal platform (160) moves forward horizontally, wherein a second articulated mechanical arm (165b) is adapted to push the sealed erected corrugated case out to a delivery station as the horizontal platform (160) moves backward,
wherein the taping assembly (125), the minor flap closing assembly (115), and the major flap closing assembly (120) are all integrated into a single machine station; and
a human-machine interface (130) adapted to control a plurality of machine operations.
2. The automated machine (100) as claimed in claim 1, wherein the erected corrugated case is formed at an exact 90-degree angle through a coordinated operation of the at least four suction cups, the minor flap closing assembly (115), and the major flap closing assembly (120).

3. The automated machine (100) as claimed in claim 1, wherein the sealing tape is Biaxially Oriented Polypropylene tape applied to seal the bottom flaps of the erected corrugated case.

4. The automated machine (100) as claimed in claim 1, wherein the human-machine interface (130) is a programmable logic controller-based system, wherein the human-machine interface (130) is adapted to store and display real-time data and historical data of the automated machine (100).

5. The automated machine (100) as claimed in claim 4, wherein the real-time data and the historical data comprises product information, stock-keeping unit tracking, production counts over defined time intervals, sealing tape consumption, machine operating time, machine downtime, and diagnostic reports for performance analysis and maintenance planning.

6. The automated machine (100) as claimed in claim 1, wherein the taping assembly (125) is adapted to move on a pneumatic linear actuator.

7. The automated machine (100) as claimed in claim 1, comprising a servo motor (170) positioned at a top portion of the automated machine (100), wherein the servo motor (170) is adapted to provide precise positioning, programming, and operational flexibility.

8. The automated machine (100) as claimed in claim 1, wherein the automated machine (100) is operated at an adjustable speed of at least six cases per minute.

9. The automated machine (100) as claimed in claim 1, comprising a mechanical sensor adapted to detect completion of a taping process, wherein the mechanical sensor identifies when the sealing tape exits the sealed erected corrugated case and triggers a cutting mechanism to cut the sealing tape at in position.

10. A method (200) to operate an automated machine for forming a corrugated case, comprising:

supplying, by an in-feeder assembly, a flat corrugated case for opening, erecting, and sealing within a controlled environment; (205)
attaching, by at least four suction cups, to one side of the flat corrugated case; (210)
expanding, by the at least four suction cups, the flat corrugated case into a box shape thereby transforming the flat corrugated case into an erected corrugated case; (215)
holding, by the at least four suction cups the erected corrugated case in position for processing; (220)
engaging and closing, by at least two pneumatically operated arms of a minor flap closing assembly, a plurality of minor flaps of the erected corrugated case; (225)
engaging and folding, by at least two pneumatically operated rods of a platform of a major flap assembly, a plurality of major flaps of the erected corrugated case after the plurality of minor flaps are closed; (230)
moving, by a horizontal platform of a taping assembly, along the sliding rail in a back-and-forth direction to facilitate sealing of the erected corrugated case; (235)
applying, by a first articulated mechanical arm of at least two articulated mechanical arms, a sealing tape to a bottom flap of the erected corrugated case while the horizontal platform moves forward horizontally; (240)
pushing, by a second articulated mechanical arm of the at least two articulated mechanical arms, the sealed erected corrugated case out to a delivery station as the horizontal platform moves backward, wherein the taping assembly, the minor flap closing assembly, and the major flap closing assembly are all integrated into a single machine station; and (245)
controlling, by a human-machine interface, a plurality of machine operations. (250)
Dated this 22nd Day of April 2025

Signature

Manish Kumar
Patent Agent (IN/PA-5059)
Agent for the Applicant