Top load cartoner

Abstract

A cartoning method including the steps of: feeding blanks from a single magazine through a single blank feeder in a first direction; forming an array of at least two blanks from the fed blanks and thereafter transporting the array for forming, loading and closing via respective robot kinetics of at least two axis motion. Carton blanks and cartons travel through a path. Robots below the path transport the cartons. Robots above the path facilitate carton forming, loading and closing. Methods and apparatus are disclosed.

1 . A cartoning method including the steps of: 
 feeding blanks from a single magazine through a single blank feeder in a first direction; and    forming an array of at least two blanks of predetermined number from said blanks.    
   
   
       2 . A method as in  claim 1  including the step of: 
 applying glue sequentially to cartons being fed from said feeder prior to the formation of said array.    
   
   
       3 . A method as in  claim 1  including the step of: 
 applying glue to said fed blanks after forming them into said array.    
   
   
       4 . A method as in  claim 1  including the further step of: 
 moving said array in a second direction perpendicular to the first direction in which carton blanks are fed from said feeder.    
   
   
       5 . A method as in  claim 1  including transporting said array to a carton forming station and there at least partially forming cartons from said blanks in said array.  
   
   
       6 . A method as in  claim 1  including the further steps of: 
 transporting cartons from said carton forming station to a loading station and there loading items into said cartons;    transporting loaded cartons to a closing station and closing loading cartons; and    discharging cartons.    
   
   
       7 . A method as in  claim 6  including transporting cartons from said carton forming station to said loading station by a robot having at least a two-axis motion.  
   
   
       8 . A method as in  claim 6  including transporting cartons from said loading station to said closing station by a robot having at least a two-axis motion.  
   
   
       9 . A method of cartoning, including the forming, transporting and loading of cartons in selected carton arrays of two or more cartons, and including the steps of: 
 feeding carton blanks onto a feed conveyor at a single infeed location from a single carton blank feeder; and    forming an array of carton blanks on a feed conveyor by said feeding.    
   
   
       10 . A method of handling carton blanks and including the steps of: 
 feeding carton blanks sequentially from a single infeed point;    applying glue sequentially to said fed blanks;    forming, at an array station, an array of blanks, having glue applied thereto; and    transferring said array away from said array station.    
   
   
       11 . A method as in  claim 9  wherein the steps of feeding and applying glue to said blanks includes moving said blanks in the same direction during said feeding and said glue applying.  
   
   
       12 . A method of cartoning wherein a plurality of operations are carried out on cartons and including the steps of conducting some of said operations in a continuous motion and some in an intermittent motion and wherein said motions are decoupled one from the other.  
   
   
       13 . A method of cartoning wherein products are loaded into cartons and including the steps of: 
 forming cartons;    transporting formed cartons to a loading station;    loading cartons; and    transporting cartons from said loading station;    wherein at least one of said steps is carried out in continuous motion and another of said steps is carried out in intermittent motion and wherein said respective motions are decoupled one from the other.    
   
   
       14 . A method as in  claim 13  wherein said forming, transporting and loading steps are all carried out by robots having at least two axes of motion and including the further step of selectively raising and lowering cartons with said robots during said cartoning.  
   
   
       15 . A method as in  claim 13  including: 
 engaging such cartons in end-of-arm tooling on a robot; and    performing a carton manipulating operation on cartons while said cartons are engaged by said tooling.    
   
   
       16 . Apparatus for handling carton blanks, said apparatus including: 
 a blank feeder defining a single infeed;    a blank conveyor oriented to receive fed blanks from said single infeed and for transferring said blanks to a glue station;    glue apparatus oriented to apply glue to blanks transported there-past; and    an array orienting station downstream of said glue apparatus.    
   
   
       17 . Apparatus as in  claim 16  and further including a blank receiving apparatus receiving fed blanks sequentially from said infeed and transferring fed blanks to said conveyor.  
   
   
       18 . Apparatus as in  claim 16  wherein said blanks are fed sequentially onto said blank conveyor in a first direction, said conveyor oriented for moving said blanks in a single direction from said infeed past said glue apparatus.  
   
   
       19 . Apparatus as in  claim 18  including transfer apparatus for moving an array of said blanks, downstream of said glue apparatus, in a second direction, perpendicular to said first direction, toward a carton forming station.  
   
   
       20 . A cartoner comprising: 
 a former robot;    a former-to-loader transport robot;    a loader robot; and    a loader-to-closer transport robot    said robots operationally interconnected to form, transport, load and further transport loaded cartons.    
   
   
       21 . A cartoner as in  claim 20  wherein said former and loader robots are oriented above a path of movement of said cartons and said respective transport robots are oriented below said path.  
   
   
       22 . A cartoner as in  claim 21  further including end-of-arm tooling respectively carried by respective ones of said robots.  
   
   
       23 . A cartoner as in  claim 22  further including at least two sets of end-of-arm tooling, each set facilitating loading of cartons oriented at a different pitch from cartons whose loading is facilitated by the other set.  
   
   
       24 . Cartoning apparatus comprising: 
 a single magazine;    a feeder for feeding blanks received from said single magazine in a first direction;    a conveyor for receiving at least two blanks defining an array of blanks; and    apparatus having motion in at least two axes for moving said array from said conveyor toward a carton forming apparatus.    
   
   
       25 . Apparatus as in  claim 24  further including a robot for transporting an array of cartons from a carton former station to a carton loading station.  
   
   
       26 . Apparatus as in  claim 25  wherein said robot is disposed beneath a path in which said array of cartons passes and said apparatus for moving said array from said conveyor toward a carton forming apparatus is disposed above said path.  
   
   
       27 . Apparatus as in  claim 25  further including two robots for transporting an array of cartons from a carton former station to a carton loading station.  
   
   
       28 . Apparatus as in  claim 24  further including a robot for transporting an array of cartons from a carton loading station to a carton closing station.  
   
   
       29 . Apparatus as in  claim 28  further including a robot for loading items into said array of cartons and wherein said robot for transporting is disposed beneath a path in which said array of cartons moves and said robot for loading items is disposed above said path.  
   
   
       30 . Apparatus as in  claim 27  further including two robots for transporting an array of cartons from a carton loading station to a carton closing station.