WO2025262000A1

WO2025262000A1 - Cardboard web feeder and cardboard web feeding method for cardboard web processing machines

Info

Publication number: WO2025262000A1
Application number: PCT/EP2025/066809
Authority: WO
Inventors: Fokke De Boer
Original assignee: Sparck Technologies BV
Current assignee: Sparck Technologies BV
Priority date: 2024-06-17
Filing date: 2025-06-16
Publication date: 2025-12-26
Anticipated expiration: 2026-12-17

Abstract

Cardboard web feeder (200) for cardboard web processing machines (208), in particular for machines for making custom-sized cardboard boxes and/or lids, comprising at least one feeding drive unit (202) adapted to move a cardboard web (204) inserted into it from at least one stack (206) of cardboard in and against a feeding direction and guide elements (216, 218) defining at least one track (214) for guiding the cardboard web (204) from said at least one feeding drive unit (202) towards a cardboard web processing machine (208) comprising a cardboard drive for moving a cardboard web (204) in and against said feeding direction, wherein said at least one feeding drive unit (202) is adapted for being alternatively controlled dependent on and independent of said cardboard drive.

Description

CARDBOARD WEB FEEDER AND CARDBOARD WEB FEEDING

METHOD FOR CARDBOARD WEB PROCESSING MACHINES

T ECHNICAL FIELD OF THE INVENTION

The invention relates to a cardboard web feeder for cardboard web processing machines, in particular machines for making custom-sized cardboard boxes and/or lids, and a method for feeding cardboard webs to such machine. The invention also relates to a cardboard web processing machine, in particular a machine for making customsized cardboard boxes and/or lids, to a method for processing cardboard webs, in particular for processing cardboard webs to form cardboard blanks for boxes and/or lids, and to a system and a method for automatically packaging varying shipment sets in custom-sized cardboard boxes. As used herein, the term "shipment set" denotes a set of one or more items to be shipped. Packaging "varying shipment sets" indicates that the number and/or the size of the items in the shipments sets to be packaged may vary from one set to the other.

TECHNICAL BACKGROUND

The present invention addresses different problems in conjunction with feeding a cardboard web, typically a fanfold (also called zig-zag folded) cardboard web to a machine processing the cardboard web, in particular to make cardboard boxes and/or cardboard lids. Some cardboard boxes have attached lids, i.e. a portion of a so-called cardboard blank, from which such a box is folded, is used to fold a lid, whereas other cardboard boxes are closed with lids folded from separate blanks. The wording "cardboard boxes and/or cardboard lids" is used herein to denote all, cardboard boxes, cardboard lids and cardboard boxes with attached lids.

Mail ordering has become a widely used way of buying goods. More and more companies offer virtual department stores, in which the customers can electronically put goods in a virtual shopping cart that later will be transferred by the respective company into a dispatch order so that in a warehouse a shipment set comprising the items ordered (and sometimes additional items such as samples, vouchers, invoices, void-fill etc.) can be assembled based on the respective dispatch order. Typically, a thus assembled shipment set is then transferred to and entered in a system for automatically packaging shipment sets in particular in custom-sized boxes.

For automating the packaging of varying shipment sets, different systems have been proposed. One approach is shown in WO 2016/059218 A1 , which discloses a system and a method for automatically packaging varying shipment sets employing two separate packings, namely an inner packing surrounding the items to be packaged in a first direction, and an outer packing surrounding the inner packing in a second direction, said second direction being substantially perpendicular to the first direction such that the inner and the outer packing form a combined package enclosing the items from all sides.

A different approach is shown in WO 2014 118629 A2 and WO 2014 117817 A1 , which teach methods and systems that allow - within the boundaries imposed by the material used - creating a fully custom-sized box, i.e. a cuboid box, of which width, length and height are adapted to the respective content of the box. It has turned out that such systems allow, in particular by using a special box design as disclosed in WO 2019 081773 A1 , packaging about 1000 and more varying shipment sets per hour.

Depending on the specific way the packaging system works, a box with or without an attached lid may be formed automatically by gripping and folding a blank. In the "International Fibreboard Case Code" published by FEFCO and ESBO, 2007, 11^th edition, many different box and lid layouts are disclosed, some of which are easy to handle in automated packaging systems, and the respective box may be closed with a lid formed from the same blank as the box or with a separately formed lid.

To increase the throughput of a packaging system, a system and a method for transporting items to a packaging station have been proposed in EP 3 674 235 A1 employing two or more arranging stations, each adapted for arranging items into shipments sets to be packaged, and multiple conveyers for transporting the shipment sets to a packaging station comprising structure for cutting and creasing custom-sized cardboard blanks and structure for folding a respective blank after a shipment set of one more items has been transported onto it. Such use of multiple conveyers allows to work in parallel on the arranging of shipment sets and to hence increase the throughput of a packaging system to a certain extent. While the known systems and methods for automating the packaging process work well for a number of applications, and in particular the system disclosed in WO 2014/117817 A1 has proven to allow packaging varying shipment sets fully automatically, it has turned out that there is still room for optimization.

A particularly limiting factor slowing down a packing process or, in general, a cardboard processing process is the feeding of cardboard web to a machine processing the cardboard web. When the end (the trailing edge) of a cardboard web supplied from a stack or a coil reaches the processing machine, the leading edge of a new cardboard web from another stack or coil of cardboard needs to be fed into the processing machine. While in large newspaper printing facilities handling several hundreds of kilometers of rather thin and hence very flexible paper webs per day feeding the printing machines with paper webs is highly automated, in cardboard handling and in particular box making and packaging facilities introducing the leading edge of a cardboard web into a respective machine is typically still done manually. An operator guides the leading edge of a new cardboard web along a track defined by guide elements such as guide rails to the respective machine, where it is then drawn in by a respective drive. Sometimes the cardboard web is simply drawn from a stack over a guiding stand having a passive rotatable element at its top that rotates with the cardboard moving over it. Such stand ensures that the cardboard web can smoothly enter the processing machine without touching the ground.

Sometimes several tracks for guiding cardboard webs from different stacks of fanfold cardboard are provided to either ensure a faster change to a new cardboard web when the cardboard web from a current stack is used up or to provide different types of cardboard for example for making boxes of different sizes and/or different strengths. However, in any case guiding the cardboard web manually to the respective machine is cumbersome and time consuming. In order to make this process more efficient, the distance between the cardboard stacks and the respective machine is typically kept rather short, which however imposes other limitations. Sometimes a cardboard web processing facility shall be erected on a site, where the spatial situation would make it preferable to have the stacks positioned rather far away from and/or on another floor than the machine using the cardboard web. Besides, stacks of cardboard are rather heavy and are usually brought to the site by fork lifters, which require additional space for maneuvering. In order to reduce waste when the remaining length of a cardboard web is not sufficient for a specific process, for example for making a specific custom-sized box, US 2021/0039913 A1 proposes a system and method for splicing the trailing edge portion of one cardboard web to the leading edge portion of another cardboard web to create a continuous cardboard web. However, this again is done manually and the thus created cardboard web is then drawn into the respective machine by a drive provided at the machine.

As the cardboard suitable for making boxes is usually rather stiff double faced corrugated cardboard, the cardboard web is typically provided in form of a stack of fanfolded stiff "plates" joined together along via transversal folds allowing the fanfolding. While the material is of course somewhat flexible, when such cardboard web is pushed back along a track leading from a stack to the machine, as is done in many processing processes, the cardboard web folds at the transversal folds, making it necessary to leave a lot of room between adjacent tracks or guide rails to allow such folding without damaging the cardboard web. For example, some custom-sized box making machines first draw the cardboard web in to cut off material for a new blank and then push the remaining cardboard web back by about 20 to 30 cm. The same is done at some machines when switching between different cardboard webs fed into the machine, for example for making boxes of different types of cardboard.

SUMMARY

In view of the aforementioned problems, it is an object of the invention to disclose an improved cardboard web feeder and a method for feeding cardboard webs to a cardboard web processing machine, allowing in particular to increase the throughput of such machines and to enable more freedom in using the space available for such machines for example by allowing longer distances between stacks of cardboard and the processing machine. It is also an object of the invention to provide an improved cardboard web processing machine and an improved system for packaging varying shipment sets as well as improved methods for processing cardboard webs and for packaging varying shipment sets. With respect to a cardboard web feeder and a feeding method, the object is achieved by a feeder according to claim 1 respectively a method according to claim 11 . Independent claims 9 and 10 related to a cardboard web processing machine respectively a system for automatically packaging varying shipment sets, i.e. for packaging items of varying size and number. Independent claims 22 and 23 relate to a method for processing cardboard webs respectively a method for automatically packaging varying shipment sets in custom-sized cardboard boxes. Advantageous embodiments are subject of the dependent claims.

According to the invention, a cardboard web feeder for cardboard web processing machines, in particular for machines for making custom-sized cardboard boxes and/or lids, comprises at least one feeding drive unit adapted to move a cardboard web inserted into it from at least one stack of cardboard in and against a feeding direction and guide elements, such as in particular guide rails, defining at least one track for guiding the cardboard web from said at least one feeding drive unit towards a cardboard web processing machine comprising a cardboard drive, wherein said at least one feeding drive unit is adapted for being alternatively controlled dependent on and independent of said cardboard drive. Note that the term "feeding direction" not necessarily denotes a straight line, but the general processing direction in which the cardboard web is moved along at least one track from a stack towards a processing machine. Note also that while guide elements such as guide rails may form one or more basically continuous tracks between one or more feeding drive units and a processing machine, the rather stiff cardboard material allows for interruptions of such tracks.

Surprisingly it has turned out that by providing an actively driven feeding drive unit adapted to move a cardboard web not only in, but also against said feeding direction, a number of problems associated with the cardboard web feeding can be solved, when the feeding drive unit is adapted for being alternatively controlled dependent on and independent of the cardboard drive of a cardboard web processing machine. As will be explained in more detail below, "being alternatively controlled dependent on and independent of said cardboard drive" denotes the ability to move a cardboard web using said at least one feeding drive unit independently of a corresponding cardboard drive of the respective processing machine. Typically, in complex systems such as packaging systems for the automated packaging of varying shipment sets, a superordinate control unit is employed to control both the cardboard web feeder and the processing machine, so that one might argue that the cardboard web feeder always is somewhat dependent on the cardboard drive of the processing machine and vice versa, but nevertheless there is a clear distinction between a situation, in which the actions of the cardboard drive of a processing machine, in particular pulling cardboard in or pushing it backwards against the feeding direction, directly affect the actions of a feeding drive unit, namely pushing cardboard forwards in the feeding direction or pulling it backwards against the feeding direction, and a situation, in which the actions of the cardboard drive of a processing machine do not directly affect the actions of a feeding drive unit, for example when only a small amount of a cardboard web remains in a track leading to the processing machine and the feeding drive unit is used to move a new cardboard web along said track towards the processing machine.

With such feeding drive unit in conjunction with the respective guide elements, it is possible to push a cardboard web from a stack over a great distance towards a respective processing machine where the cardboard web is processed, for example cut, creased and folded to make boxes or lids, making feeding the leading edge of a cardboard web from a new stack of cardboard to the machine much faster and easier even in cases where the cardboard stacks are placed rather far away from the processing machine. The invention also leads to an increased throughput of the processing machine as the leading edge of a new cardboard web can be readily moved close to the trailing edge of a currently processed cardboard web and then be immediately inserted into the machine when the end of a previously processed cardboard web has been processed. Note that it would even be possible to (automatically or manually) attach the leading edge of the new cardboard web to the trailing edge of the currently processed cardboard web, which could be done in or at the processing machine.

A particular advantage of a cardboard web feeder according to the invention is that once the leading edge has been fed into the machine, the machine (i.e. a control unit controlling the machine) can take over control of the feeding drive unit and adjust its speed and its transport direction as will be explained in more detail below. For example, when the cardboard drive of the processing machine moves the cardboard web against the feeding direction, the feeding drive unit may also pull the cardboard web back thus preventing unwanted folding of the web along the track between the feeding drive unit and the machine.

In an advantageous embodiment said at least one feeding drive unit is adapted for receiving a cardboard web alternatively from at least two separate cardboard stack positions. This enables that e.g. a first and a second stack of fanfold cardboard webs are positioned in a row next to each other so that the leading edge of cardboard from the second stack can be inserted into the feeding drive unit as soon as the trailing edge of the cardboard web from the first stack has left the feeding drive unit, or in other words when the first stack is used up. To further facilitate feeding cardboard webs from different stacks in a row of stacks, the feeding drive unit may be pivotable about an axis parallel to the leading edges of the cardboard webs, which typically are parallel to the transverse folds in the fanfolded cardboard webs.

In a further advantageous embodiment, which may comprise features of the aforementioned embodiments, the guide elements define at least two separate tracks for guiding a cardboard web from said at least one feeding drive towards said cardboard web processing machine. This enables several feeding options. If only one feeding drive unit is provided, a switch may divert a cardboard web from a new stack into one track as soon as the trailing edge of cardboard web from a previous stack has left the feeding drive unit and is still in another track, where it is being moved by a cardboard drive of the processing machine.

In a further advantageous embodiment, which may comprise features of the aforementioned embodiments, the cardboard web feeder comprises multiple feeding drive units, each feeding drive unit adapted for being alternatively controlled dependent on and independent of said cardboard drive of the cardboard web processing machine, wherein said guide elements define separate tracks for guiding a cardboard web from each of said multiple feeding drive units towards the cardboard web processing machine. This allows that, while a currently processed cardboard web is still moved forwards and backwards along one of the tracks with the help of the respective feeding drive unit at this track, one or more cardboard webs are moved towards the processing machine using the other tracks and feeding drive units. Once the currently processed cardboard web is used up, a cardboard web from another track may then easily be inserted into the processing machine, which can be done manually or automatically. For this purpose, an automated switch may be provided at the processing machine, which connects the respective track containing the leading edge of the new cardboard web that shall be processed next with the processing machine. Once such connection is made, the respective feeding drive unit may advance the cardboard web into the processing machine, which may then take over control of the feeding drive unit as will be explained in more detail below.

When the cardboard web feeder comprises several tracks, a merging unit, for example in form of the above mentioned switch, for merging at least some of said tracks into a single track may be provided. Such merging unit may comprise an active switch, i.e. a driven switch that is pivoted about an axis, or a passive "funnel-like" element into which the tracks lead. Merging separate tracks into one track allows saving material for the tracks and making the entire set-up more compact.

In a further advantageous embodiment, which may comprise features of the aforementioned embodiments, a number of cardboard centering guide units are arranged along said one or more tracks. Due to the inherent material properties of the cardboard web, the tracks can generally have a rather "open" configuration, and e.g. two bottom and two top rails may already provide sufficient guidance for advancing cardboard web from a stack toward a processing machine. Depending on the length of such track, it will nevertheless often be useful to center the cardboard web every now and then respect to the track. Centering guide units may be funnel-like elements provided at a fixed distance to the left and the right of a respective track, while said guide elements provide guidance for the cardboard web towards the bottom and the top of such tracks. The centering guide units may also be active elements that may be automatically adjustable to different cardboard web widths.

In a further advantageous embodiment, which may comprise features of the aforementioned embodiments, the cardboard web feeder comprises at least one support drive unit, said at least one support drive unit arranged along said at least one track and adapted to move a cardboard web in and against a feeding direction along said track, and said least one support drive unit adapted for being alternatively controlled dependent on the cardboard drive and dependent on the feeding drive unit moving a cardboard web in the feeding direction along said one of said track. Such support drive units are particularly advantageous when the cardboard web has to be fed over a long distance from a respective stack to the processing machine. As will be explained in more detail later, for several reasons it is advantageous to be able not only to feed a cardboard web into a processing machine, but also to pull it backwards against the feeding direction. If the trailing edge of the cardboard web that is currently being processed has already left the respective feeding drive unit, the cardboard may still be engaged by the support drive unit, which may then provide the advantages incurred with being able to push forward and pull back the cardboard web along the respective track leading to the processing machine.

In a further advantageous embodiment, which may comprise features of the aforementioned embodiments, the cardboard web feeder comprises at least one sensor element for detecting the presence of a cardboard web in and/or at the at least one feeding drive unit and/or the at least one support drive unit. With such a sensor, multiple advantages can be achieved, and the entire feeding process can be more or even fully automated. For example, with such sensor signaling means adapted for outputting a signal indicating that no cardboard is present a feeding drive unit and/or a support drive unit may be controlled. Such signaling means may comprise optical or acoustical means such as lights and speakers indicating to an operator that a cardboard web has been used up and needs to be replaced. The signaling means may also be coupled with a central control unit that may then generate an automatic request for replacement of an empty cardboard stack. Depending on the respective facilities, such replacement may be done fully automatically by respective transport robots. Also, when the leading edge of a new cardboard web, which shall be introduced into a feeding drive unit, approaches the respective feeding drive unit, the feeding drive unit may automatically start pulling the leading edge in.

In a further advantageous embodiment, which may comprise features of the aforementioned embodiments, the cardboard web feeder comprises at least one robotic cardboard inserting unit adapted for gripping a leading edge of a cardboard web from a stack of cardboard and inserting it in the at least one feeding drive unit. This facilities further automation of the feeding process.

A cardboard web processing machine, in particular a machine for making custom-sized cardboard boxes and/or lids, according to invention comprises structure for cutting and creasing cardboard cut off from a cardboard web to form cardboard blanks, optionally structure for folding boxes and/or lids from said blanks, and at least one cardboard web feeder as set out above. A system for automatically packaging items varying in size and number in custom-sized boxes according to invention comprises such box making machine and either structure for placing the item(s) to be packaged on a cardboard blank prior to folding it to form a box or structure for placing the item(s) to be packaged in a custom-sized box. Note that the term "cutting" is used to denote different forms of separating portions of a cardboard web, including incising or die cutting (punching out), and accordingly structure for cutting may include rotating or reciprocating knifes, lasers, die cutters etc. Structure for creasing may include crease rollers or moving stamps, and structure for folding the cardboard may include moveable grippers and flaps.

In such machine for making custom-sized boxes respective such system for packaging items in custom-sized boxes, a first step is obtaining information on the outer dimensions length, width and height of the shipment set to be packaged and calculating based on this information the layout of a custom-sized cardboard blank (sometimes called template or piano) comprising different so called panels, which are delimited from each other by crease lines or indentations and incisions allowing the panels to be folded in order to create the box wanted. From a cardboard web supplied as laid out above a piece having the calculated size is then cut-off, indented and incised (not necessary in this order) to form the blank. It should be noted that due to the thickness of the cardboard, the so-called crease lines like the aforementioned folds are not thin lines as for folding paper, but are rather "crease grooves". However, following the terminology common in the art, the term crease line is used herein.

Typically, hot melt glue is used in such box forming process, and accordingly the machines and systems will comprise structure for attaching the respective panels to each other including a glue unit for applying hot melt glue to one or both of two overlapping panels. In another embodiment tape is used to attach the panels.

For making a custom-sized box, information about a shipment set to be packaged can be acquired in multiple ways, and the invention advantageously allows using the most appropriate way of acquiring such information. For example, an image of the complete or parts of the shipment set may be taken and/or RFID tags, barcodes, QR codes etc. of one or more items of the shipment set may be scanned, and accordingly the machine/system may comprise a camera, a laser scanner, an RFID tag reader, a barcode reader, a QR code reader, a scale, a database, a contact-based coordinate measuring machine with a contact probe, a current meter for monitoring the current of a conveyor or a transport element transporting the respective shipment set.

The cardboard web feeder and the machine/system may be controlled by one or more control units comprising for example a computer or one or more dedicated processors, nontransitory processor-readable media (such as for example volatile memory such as random access memory (RAM), non-volatile memory such as read only memory (ROM), storage media such as a magnetic hard disk drive, optical disk drive, solid state drive (SSD) or FLASH drive) communicatively coupled with the processor(s).

A method for feeding cardboard web to a cardboard web processing machine, in particular to a machine for making custom-sized cardboard boxes and/or lids, said machine comprising a cardboard drive engaging with a cardboard web to move it in and against a feeding direction, according to the invention comprises employing at least one feeding drive unit engaging with a cardboard web to move it from at least one stack of cardboard in and against a feeding direction along at least one track for guiding a cardboard web from said at least one feeding drive unit towards said cardboard drive, when said cardboard drive is engaged with a cardboard web and said at least one feeding drive unit is engaged with the same cardboard web, controlling said feeding unit dependent on said cardboard drive, and when said cardboard drive is not engaged with a cardboard web, controlling said at least one feeding drive unit independent of said cardboard drive.

Such method allows amongst others that when there is no continuous cardboard web between said cardboard drive and said at least one feeding drive unit, a cardboard web from a stack of cardboard is moved forward said feeding direction along said at least one track towards said cardboard drive, without needing a human operator pulling the cardboard web from the stack to the processing machine.

In an advantageous embodiment, the method comprises, when said cardboard drive is engaged with a cardboard web guided along said at least one of said track and said at least one feeding drive unit is engaged with another cardboard web guided along the same track, controlling said feeding unit dependent on said cardboard drive. This facilitates that a new cardboard web is fed towards the processing machine to be readily used without entangling with the cardboard web that is currently being processed.

In a further advantageous embodiment, which may comprise features of the aforementioned embodiments, the method comprises controlling at least one support drive unit, which is arranged along said at least one track and adapted to engage with a cardboard web to move it in and against said feeding direction, such that when said cardboard drive is engaged with a cardboard web and said at least one support drive unit is engaged with the same cardboard web, said at least one support drive unit is controlled dependent on said cardboard drive, and when said at least one feeding drive unit is engaged with a cardboard web, while said cardboard drive is not engaged with the same cardboard web, and said at least one support drive unit is engaged with the same cardboard web, said at least one support drive unit is controlled dependent on said at least one feeding drive unit. With one or more support drive units controlled in this manner, it is possible to feed a cardboard web over a quite long distance from a stack to a processing machine while ensuring the advantages of being able not only to move cardboard web in a feeding direction but also against it.

In a further advantageous embodiment, which may comprise features of the aforementioned embodiments, the method comprises detecting the presence of a cardboard web in and/or at the at least one feeding drive unit and/or the at least one support drive unit and creating, based on the result of said detecting, at least one of alarm signals and override control signals. Such alarm signals may be outputted to the attention of a human operator or may be used to trigger certain automated actions such as starting an automated process for getting a new cardboard stack. Override control signals may be used to trigger actions like stopping a cardboard web advancing along a track, in which the trailing edge of a cardboard web that is currently being processed is still present.

In a further advantageous embodiment, which may comprise features of the aforementioned embodiments, controlling said at least one feeding drive unit and said at least one support drive unit dependent on said cardboard drive comprises setting the conveying speed of said at least one feeding drive and/or said at least one support drive unit to about 99 - 95 % of the conveying speed of said cardboard drive, when a cardboard web is moved in said feeding direction, and to about 101 - 105 % of the conveying speed of said cardboard drive, when a cardboard web is moved against said feeding direction. This allows to stretch/straighten the cardboard web, which due to its inherent properties tends to fold at the transvers folds being present in the cardboard web from fanfolding.

The same effect may be achieved with a further advantageous embodiment of the method, which may comprise features of the aforementioned embodiments, according to which controlling said at least one feeding drive unit and/or said at least one support drive unit dependent on said cardboard drive comprises starting said at least one feeding drive unit and/or said at least one support drive unit about 5 - 50 ms after starting said cardboard drive, when a cardboard web is to be moved in said feeding direction, and about 5 - 50 ms before starting said cardboard drive, when a cardboard web is to be moved against said feeding direction.

Another approach also achieving the aforementioned effect of straightening the cardboard web according to another advantageous embodiment, which may comprise features of the aforementioned embodiments, is to control said at least one feeding drive unit and/or said at least one support drive unit dependent on said cardboard drive such that when said cardboard drive is started to move a cardboard web in said feeding direction, the cardboard web is moved about 5 - 30 mm in said feeding direction with said cardboard drive before starting said at least one feeding drive unit and/or said at least one support drive unit, and when a cardboard web is to be moved against said feeding direction, said cardboard web is moved about 5 - 30 mm against said feeding direction with said at least one feeding drive unit and/or said at least one support drive unit before starting said cardboard drive.

In a further advantageous embodiment, which may comprise features of the aforementioned embodiments, controlling said at least one feeding drive unit independent of said cardboard drive comprises setting the conveying speed of said at least one feeding drive unit to about 5 - 25 % of its maximum conveying speed, when a new cardboard web is inserted into it. During normal operation, cardboard web may be processed with a speed of about 0,5 m/s. In particular, when a human operator feeds the leading edge of a cardboard web from a new stack into a feeding drive unit, for security and convenience reasons it can be advantageous not to draw in the cardboard web with rather high speed, which might rip the cardboard web out of the hand of the operator.

In a further advantageous embodiment, which may comprise features of the aforementioned embodiments, the method comprises determining the position of the trailing edge of a cardboard web along said at least one track engaged by said cardboard drive and controlling the position of the leading edge of a following cardboard engaged by said at least one feeding drive unit and/or said at least one support drive unit such that said leading edge does not overtake that trailing edge. This prevents collisions between cardboard webs travelling along the same track.

In a further advantageous embodiment, which may comprise features of the aforementioned embodiments, the method comprises determining the positions of the leading edges and the trailing edges of all cardboard webs present in a cardboard web feeder as laid out above using at least one of: calculating the position of a trailing edge based on information about the overall length of the respective cardboard web being currently processed and the length of a portion of this cardboard web already processed and the length of the respective track along which said cardboard web is guided to the processing machine, sensor elements along the respective tracks along which cardboard webs are guided to the processing machine, markers on the respective cardboard web and respective counters provided at the feeding drive units, number of turns made by a feeding drive unit and/or a support drive unit comprising drive rollers.

Such sensor elements may comprise photo cells, light barriers and many different types of contact or non-contact sensors like cameras and the like. Markers on the respective cardboard web can be optical markers, and respective counters can comprise charge-coupled devices adapted for detecting the presence of such markers. Also, the transvers folds present in the cardboard web from fanfolding can be used as markers. While depending on the layout of the cardboard stacks, such transvers folds may only be present every 1 to 2 m in cardboard web, it is for most cases not necessary to determine the position of a leading respectively a trailing edge very precisely. If the position is known with a relatively large tolerance of e.g. 1 to 2 m, it is easily possible to control the cardboard drive of the processing machine and the drive units such that there is always a certain minimum distance between the trailing edge of a cardboard web present in one track and the leading edge of a cardboard web following in the same track. Typically, the different drive unit comprise drive rollers engaging the cardboard that, and these rollers have known circumferences, from counting the number of turns made by the rollers, it can be calculated, how far cardboard web has been moved forwards or backwards by the respective drive unit.

In a further advantageous embodiment, which may comprise features of the aforementioned embodiments, the method comprises controlling a plurality of said feeding drive units, each adapted to engage with a cardboard web to move it in and against said feeding direction along one of a plurality of tracks, such that the feeding drive unit engaging with a cardboard web currently processed by said processing machine and travelling along one of said plurality of tracks is controlled dependent on said cardboard drive and such that at least one remaining feeding drive units is controlled to move a cardboard web along another one of said plurality of tracks to a waiting position close to said processing machine.

This enables that a new cardboard web is "parked" close to a processing machine in a waiting position, so that once the cardboard web being currently processed has been used up, the new cardboard web could immediately be fed into the processing machine.

According to the invention, a method for processing a cardboard web fed from a stack of cardboard into a cardboard web processing machine, in particular a machine for making custom-sized cardboard boxes and/or lids, comprises cutting and creasing the cardboard web to form cardboard blanks, optionally folding boxes and/or lids from said blanks, and employing a method for feeding a cardboard web as laid out above. According to the invention, a method for automatically packaging varying shipment sets in custom-sized cardboard boxes, comprises preparing a shipment set of one or more items to be shipped, calculating the layout of a cardboard box blank for a cardboard box comprising a bottom panel, based on said calculated layout, cutting and creasing a cardboard web fed from a stack of cardboard into a box making machine to form a cardboard blank for a cardboard box for said shipment set, placing the shipment set on said bottom panel prior or after folding a box out of said cardboard blank, and employing a cardboard web feeding method as laid out above.

Further details and advantages of the invention will become apparent from the following detailed description of embodiments in conjunction with the drawing, which comprises five drawing figures.

BRIEF DESCRIPTION OF THE DRAWING

Fig. 1 is a schematic drawing of a prior art system for packaging items varying in size and number in custom-sized boxes, said system and its operation being subject to improvement by the present invention.

Fig. 2 is a schematic drawing of a first embodiment of a cardboard web feeder according to the invention.

Fig. 3 is a schematic drawing of a second embodiment of a cardboard web feeder according to the invention.

Fig. 4 is a schematic side view of a feeding drive unit according to the invention.

Fig. 5 is a schematic perspective view of a support drive unit according to the invention.

Fig. 6 is a schematic perspective view of a centering guide unit according to the invention.

Fig. 7 is a schematic perspective view of a support drive unit and a centering guide unit connected by a track. Fig. 8 is a schematic perspective view of the entrance portion of a merge unit connected to three tracks.

Fig. 9 is a schematic drawing of a system for packaging items varying in size and number in custom-sized boxes comprising a cardboard web feeder according to the invention in one arrangement.

Fig. 10 is a schematic drawing of a system for packaging items varying in size and number in custom-sized boxes comprising a cardboard web feeder according to the invention in another arrangement.

DESCRIPTION OF PREFERRED EMBODIMENTS

Fig. 1 can be regarded as a schematic drawing explaining the principle of a packaging process of a system as disclosed in WO 2019/081773 A1 . The invention can advantageously be used in conjunction with such systems.

The packaging system 100 shown in Fig. 1 provides a sequence of processing stages with a receiving unit 102, a cutting and creasing station 104, a folding station 106, a lid placing station 108 and a final processing station including a label printing and application unit 110.

A cardboard web 112 is supplied from a stack 114 of fanfolded cardboard to the cutting and creasing station 104, where in a first step a piece of cardboard as required to make a certain box is cut-off from the cardboard web 112. This piece is then further treated to form a so-called blank for folding the specific box. A common box layout comprises different panels, in particular a bottom panel, on which one or more items to be packaged will be placed, side panels, end panels and corner panels. In the cutting and creasing station 104 slots between the corner panels and the side panels are punched out, and crease lines to delimit the respective panels from each other and to thus produce a blank for a custom-sized box are introduced.

The respective dimensions of the panels of a custom-sized box are calculated based on information about the shipment set to be packaged, and the system comprises for this purpose a calculating unit, which can form part of a control unit for controlling the complete packaging system and which may for example be integrated in the receiving unit 102, where the shipment sets 116, 118 and 120, which shall be packaged, are placed and assembled one after the other. In general, it should be understood that in some embodiments the entire packaging process including the cardboard web feeder and the feeding process according to the invention can be controlled by using one dedicated computing unit, such as in particular a programmable logic controller. Nevertheless, seen from a functional/logical viewpoint, the packaging process and the packaging system can be divided in stations. In this sense, a station can for example be a conveyor, and one might say that the automated packaging system with its integrated control unit(s) configures the processing stations. In some embodiments, one might say the automated packaging system obtains the information on the shipment set and configures the processing stations to perform their work in a specific way. Thus, the control unit may be an integral part of a respective packaging system including the feeder or may be a separate system influencing the packaging system either automatically or manually.

In the situation shown in Fig. 1 , a custom-sized open box has just been folded in the folding station 106 and is about to be closed by a lid to be folded from a respective lid blank 122 already positioned in the lid placing station 108. Such lid blank 122 may be prepared in a manner similar to the box itself, but may, depending on the chosen box layout, not comprise corner panels. The lid blank 122 may be produced in a corresponding lid making machine and then gripped and transported to the lid placing station 108.

Of the box, two corner panels 124 and 126, and a side panel 128 are visible in this view. The shipment sets 116, 118, 120 to be packaged are transported one after the other via conveyor belts through a laser scanning unit 130, which measures the outer dimensions of the shipment sets passing through the unit in order to obtain information on the desired inner dimensions length, width and height a box needs to have in order to receive the items or the arrangements of items as they are, i.e. without re-arranging the items. Of course, the system could also be provided with structure for arranging the items in a certain manner for example to reduce the volume of a box needed. However, in this schematic drawing a simple and fast working embodiment is shown. The created cardboard blank is transported from the cutting and creasing station 104 to the folding station 106, where the item or the items to be packaged are put on top of the bottom panel of the respective blank cut and creased in the cutting and creasing station 104. Respective grippers and folders like the gripping and folding units 132 and 134 fold the box around the item(s) to be packaged.

When the respective blank is transported from the station 104 to the station 106, it passes, in this embodiment, a glue application unit 136, which applies hot melt glue to the parts of the side panels, which are to be brought into contact with the corner panels.

To close the box, in this embodiment the lid placing station 108 is provided, which as indicated by the double-sided direction arrows is moveable upwards and downwards, forwards and rewards in the transport direction of the items respectively the boxes. Similar to the blanks for the box, based on the calculated dimensions a blank 122 for the lid is produced and picked up by the lid placing station 108 with suction grippers.

In this schematic drawing, only flap folding units 138 and 140 of the lid placing station 104 are shown. A gluing unit 142 applies hot-melt glue to end panels and side panels of the lid, which is placed on top of the box that just has been erected, upon which the flaps of the lid are folded down and closed. The thus closed boxes 144, 146 are then transported via respective conveyor belts to a label printing and application unit 110, which puts a label including for example the address of the recipient and postage on the boxes, which then can be picked up and further transported. The lid can be created from the same cardboard supplied as the box, in case of which the cutting and creasing station may be set up to produce not only a blank for the box, but also a blank for the lid, which may then be transported via respective conveyor belts to the lid placing station, which picks up the lid and puts it on top of the box.

It should be understood that the packaging system shown in Fig. 1 is presented for facilitating understanding the packaging process and is of rather simple nature. In modern high speed packaging systems that allow packaging 1000 and more shipment sets per hour a packaging process typically comprises between ten and twenty stages, and accordingly a high number of transportation means like conveyor belts or transportation fingers are provided. Depending on the general layout of the packaging system, some folding elements used for folding the box may also be used for folding the flaps of a lid, while typically the closing of the box will happen in a separate station so that separate folding elements will be provided for folding the lid. However, the general mechanics of the different folding elements are identical or highly similar, as will be understood by an expert in the art from the disclosure provided herein.

As was hitherto common, the cardboard web 112 is simply drawn by a cardboard drive (not shown) in the cutting and creasing station 104 from a stack 114 over a guiding stand 148 having a passive freely rotatable element denoted in its entirety by 150 and comprising three wings 152, of which only two are provided with reference numbers. In use, i.e. when a cardboard web 112 is drawn over the rotating element 150, the wings 152 are rotated about an axis 154. The distance between the free outer ends of the wings 152 is set to correspond exactly to the length of the panels 156 formed by fanfolding the cardboard web 112 into the stack 114. Note that in this schematic drawing the stack 114 is shown as a box, whereas it is in fact comprised of numerous zig-zag folded panels 156.

As the cardboard web 112 is stiff per se (as it is usually double faced corrugated cardboard), the cardboard web 112 only bends noticeably at the transverse folds delimiting the panels 156 from each other. For sake of clarity, only some panels 156 have been provided with reference numbers. When cardboard web 112 is drawn over the passive freely rotatable element 150, the wings 152 more or less automatically, or with the aid of a human operator, align with the transverse folds, thus supporting the cardboard web 112 and ensuring, that with a slight curve the cardboard web 112 can be smoothly drawn into the cutting and creasing station 104.

When the stack 114 is used up, a new stack is placed at the stand 148, and an operator manually guides the leading edge of the new cardboard web over the rotating element to the cutting and creasing station 104, where a cardboard drive can engage with it and move it forwards and backwards. As explained above, during processing the cardboard web 112 it is common to not only draw it into the respective processing machine, here the cutting and creasing station 104, but also to push it backwards against the feeding direction. Systems like the one shown in Fig. 1 often are adapted for being fed from two or more separate cardboard stacks. For example, Fig. 2 of EP 3 521 006 B1 shows a cutting and creasing station being fed from two cardboard stacks, and EP 2 951 010 A1 describes cutting a method and a system for cutting on the fly requiring a retraction of the cardboard.

To improve the feeding process, according to the invention a cardboard web feeder is proposed. Fig. 2 is a schematic drawing showing an embodiment of such feeder, denoted in its entirety by 200, which in this example comprises three feeding drive units 202, each feeding unit 202 adapted to move a cardboard web 204, when it is inserted into it from, one of three separate stacks 206 of cardboard web 204 in and against a feeding direction towards and away from a cardboard web processing machine 208, which may in particular be a machine for making custom-sized cardboard boxes and/or lids and of which only a part is shown in Fig. 2. The cardboard web processing machine 208 may for example be a cutting and creasing station 104 as shown in Fig. 1 .

In the shown situation, no cardboard web 204 has been inserted in any of the feeding drive units 202 and the cardboard webs form three separate stacks 206 of fanfolded cardboard web 204, each resting on a pallet 210. In this embodiment, an operator would feed the leading edge 212 of a cardboard web 204 into the respective feeding drive unit 202, which engages with the respective cardboard web 204 for example via driven rollers and corresponding pressing rollers and can then move the respective cardboard web 204 in and against a feeding direction towards and away from the cardboard web processing machine 208 along one of in this case three tracks 214. Each feeding drive unit 202 may be associated with one or more respective sensor elements for detecting the presence of a cardboard web in and/or at the respective feeding drive unit 202, allowing amongst others to trigger an automated "intake" process: when the operator brings a leading edge 212 of a cardboard web 204 towards a feeding drive unit 202, the driven rollers in the feeding drive unit 202 may start turning until the feeding drive unit 202 has safely engaged with the cardboard web 204. During such intake process, the conveying speed of the feeding drive unit 202 may be set to about 5 - 25 % of its maximum conveying speed, so that the cardboard web 204 is not ripped out of the hand of the operator. The entire intake process may be fully automated by providing respective robotic cardboard inserting units adapted for gripping a leading edge 212 of a cardboard web from a stack 206 of cardboard and inserting it in a feeding drive unit 202. In the shown embodiment, each track 214 is formed by guide elements in the form of upper guide rails 216 and lower guide rails 218, which define the paths the cardboard webs 204 can take. Due to the nature of the cardboard material typically used in conjunction with the invention, namely double faced corrugated cardboard, the cardboard web 204 will bend easily only at the transverse folds delimiting the panels that make up the cardboard web 204, and the distance between the upper guide rails 216 and the lower guide rails 218 has been set to ensure that a cardboard web 204 can smoothly travel along the tracks 214. How many parallel guide rails are used to form the upper and lower boundaries of each track 214 depends on the widths of the rails and the width of the cardboard to be guided. Typically, two to four parallel lower guide rails 218 will be used to form the lower boundaries of each track 214, and two to four parallel upper guide rails 216 will be used to form the upper boundaries of each track 214. The outer rails in each track may be elongated L-shaped profiles also limiting the tracks to the left and the right. Instead of using L-shaped profiles, which typically cannot be easily bent to make curved tracks, a number of cardboard centering guide units 220 may be arranged along the tracks 214. Such centering guide units may be passive funnel-like elements provided at a fixed distance to the left and the right of a respective track 214, or may also be active elements that may be automatically adjustable to different cardboard web widths.

In the shown embodiment, the rails 216, 218 are made from flexible plastic material having a low friction coefficient, such as for example an ultra-high molecular weight low pressure polyethylene. Along some straight passages of the tracks, stiff upper and lower support beams 222, of which only some are provided with reference numbers, have been provided. While the upper guide rails 216 start at the feeding drive units 202, the lower guide rails 218 run past the feeing drive units 202 towards the respective cardboard stack 206, so that they provide guidance already when feeding a leading edge of a new cardboard stack into a feeding drive unit and also when the cardboard is then drawn into the feeding drive unit.

While in the shown embodiment each feeding drive unit 202 is set up for being fed from a more or less fixed cardboard stack position, the feeding drive units 202 may be adapted for receiving a cardboard web from different cardboard stack positions. For example, the feeding drive unit 202 in the middle of the shown arrangement of three feeding drive units 202 may be pivotable to receive cardboard web not only from the stack 206 in the middle, but, when empty, also from the other stacks. Of course, in such case the lower guide rails 218 and also the scaffold supporting the feeding drive units 202 and the tracks 214, must allow such feeding from different stack positions. The scaffold comprises piles 224 and beam 226, of which only some have been provided with reference numbers. Also, instead of a pivotable feeding drive unit, it may be foreseen to feed cardboard from two stacks via two feeding drive units into a single track, which could also ensure very fast "refill" of the track in case one stack is empty.

Seen in the feeding (processing) direction from the stacks 206 to the cardboard processing web machine 208, the tracks 214 end at the cardboard processing web machine 208, where a merge unit 228 may be provided to either merge the tracks into a single track or bring the track that is currently in use, i.e. the track, along which cardboard currently being processed by the cardboard web processing machine 208, in alignment with a respective cardboard drive in the cardboard web processing machine 208. To do this, the merge unit 228 may for example be moved up and down in front of the cardboard processing web machine 208. Merge unit 228 may also be an automated switch, which connects the respective track with the cardboard web processing machine 208 so that the cardboard web 204 can be fed into the cardboard web processing machine 208. Such merge unit may also be arranged further downstream in the processing direction just before a cutting and creasing station, which advantageously facilitates fast switching between tracks to optimize cardboard usage. Fig. 8 provides a more detailed view of the entrance portion of the merge unit 228 connected to three tracks.

Fig. 3 is a schematic drawing of another embodiment of a cardboard web feeder 200' according to the invention. The set-up is highly similar to the one shown in Fig. 2, so that the description is focused on the differences, and only some of the already described parts have been provided with reference numbers.

The feeder 200' is adapted for feeding cardboard webs from stacks 206 over a rather long distance to a cardboard web processing machine 208, and hence the tracks 214 have been extended. Accordingly, the scaffold comprises some additional piles 230 and some additional beams 232, of which only some have been provided with reference numbers. Along each track 214 about half way between the respective feeding drive unit 202 and the cardboard web processing machine 208, a support drive unit 234 is arranged, which is adapted to move a cardboard web in and against the feeding direction along the respective track and is also for being alternatively controlled dependent on the cardboard drive of the cardboard web processing machine 208 and dependent on the feeding drive unit 202 moving a cardboard web in the feeding direction along said one of said tracks. The need for additional support drive units 234 depends in particular on the additional distance to be bridged, type of cardboard that must be transported and height differences to be covered in or against the feeding direction. Such support drive units 234 may be of the same type as the feeding drive units 202 or may have a slightly different configuration. Figures 4 and 5 show a feeding drive unit (Fig. 4) and a support drive unit (Fig. 5) from different perspectives, which are highly similar to each other, but differ for example in the guides for the cardboard web.

Fig. 4 is a schematic side view of a feeding drive unit 202. In this embodiment, the feeding drive unit 202 comprises two sensors 236 and 238 for detecting the presence of cardboard web in or near the feeding drive unit 202. Such sensors may for example be light barriers, and the arrows 240 and 242 indicate the "viewing direction" of the sensors 236 and 238.

In this embodiment, the feeding drive unit 202 comprises a funnel-like entrance 244, formed by two guide plates 246 and 248.

In use, a cardboard web is driven in and against the feeding direction using driven rollers 250 arranged along a first shaft 252 and corresponding counter rollers in the form of somewhat flexible so-called no-crush rollers 254, also known as soft touch or lamellar wheels, arranged along a second shaft 256. The driven rollers 250 on the first shaft 252 are typically rollers with an elastic rubberlike surface for engaging with the cardboard web. The corresponding counter rollers 254, which are typically not driven but can freely rotate when in touch with a moving cardboard web, have a similar surface.

Fig. 5 is a schematic view onto the first shaft 258 of a support drive unit 234. Along a driven first shaft 258 some rollers 260 arranged to be positioned close to a cardboard web guided through the support drive unit 234. When assembled, corresponding (typically non-driven) rollers are positioned on a second shaft and arranged to ensure that the driven rollers 260 perfectly engage with the cardboard web to drive it forwards and backwards. The support drive unit 234 is of similar design as the feeding drive unit 202, and in this embodiment the rollers inside the feeding drive unit 202 are arranged similarly to the rollers in the support drive unit 234. Guide rail mounting elements 262 are provided to connect the support drive unit 234 to upper and lower guide rails as shown in Fig. 7.

One exemplary manner of operating a feeder 200 as shown in Fig. 2 is the following: Assuming that two of the cardboard stacks 206 have fanfolded cardboard web 204 of a type used most often upon operation of the cardboard web processing machine 208, whereas the third stack 204 contains cardboard of a different type. The operator takes, one after the other, the leading edge 212 of each stack and brings it towards the respective feeding drive unit 202, where its presence is detected by respective sensors and the start of the respective feeding drive units 202 is triggered. The cardboard webs 204 from the stacks 206 are fed via the respective tracks 214 towards merge unit 228, where a selected one of the cardboard webs 204 is fed into the cardboard web processing machine 208 for being processed. A cardboard drive in the cardboard web processing machine 208 engages with the cardboard web 204, and the respective feeding drive unit 202 at the track 214 guiding the cardboard web 204 chosen for processing is now controlled dependent on said cardboard drive: if the cardboard drive pulls the cardboard web 204 into the machine 208, the feeding drive unit 202 pushes it towards the machine 208, and if the cardboard drive pushes the cardboard web 204 back into the track, the feeding drive unit 202 pulls it towards the stack, this prevents unwanted folding of the cardboard web and can even be used to straighten the cardboard, which due to the fanfolding tends to fold at the transverse folds. Such straightening effect can be achieved in different manners, applied alternatively or cumulatively: when the cardboard web 204 is moved in the feeding direction, i.e. is drawn into the machine 208, the conveying speed (also called transport speed) of the feeding drive unit (and of any support drive unit present along the respective track 214) is set to about 99 - 95 % of the conveying speed of the cardboard drive, and when the cardboard web 204 is moved against the feeding direction, i.e. is pushed back from the machine 208, the conveying speed of the feeding drive unit (and again of any support drive unit present along the respective track 214) is set to about 101 - 105 % of the conveying speed of the cardboard drive. Alternatively, or additionally, the feeding drive unit 202 (and any support drive unit present along the respective track 214) may be started about 5 - 50 ms after starting said cardboard drive, when a cardboard web is to be moved in said feeding direction, and about 5 - 50 ms before starting said cardboard drive, when a cardboard web is to be moved against said feeding direction.

Alternatively or additionally, the feeding drive unit 202 (and any support drive unit present along the respective track 214) may be controlled such that when the cardboard drive is started to move the cardboard web 204 in the feeding direction, the cardboard web 204 is moved about 5 - 30 mm in said feeding direction with the cardboard drive before starting the feeding drive unit 202 (and any support drive unit present along the respective track 214) and when the cardboard web 204 is to be moved against the feeding direction, the cardboard web 204 is moved about 5 - 30 mm against said feeding direction with the feeding drive unit 202 (and any support drive unit present along the respective track 214) before starting the cardboard drive.

In one embodiment, the difference between the conveying speed of the feeding drive unit (and again of any support drive unit present along the respective track) and the conveying speed of the cardboard drive, also called "speed delta", is fixed at a statically defined value, while in other embodiments it may be configurable by a user or by a self-learning algorithm. The same applies cum grano salis for the aforementioned time difference in starting the feeding drive unit and starting the cardboard drive (also called "time delta") and also for the aforementioned differences in moving the cardboard web some distance in or against said feeding direction with the cardboard drive respectively with the feeding drive unit (also called "distance delta"). In another embodiment the speed delta, time delta or distance delta applied is dependent on the distance the cardboard web has to be transported in the feeding direction or against the feeding direction, to prevent overstretching of the cardboard web. For example, for short distances a higher speed delta may be applied than for longer distances.

When the cardboard web 204 is used up or when a cardboard web of another type shall be processed, the merge unit 228 switches to the track 214 containing the desired cardboard web, which allows very fast changes and increases the throughput of the machine 208. To allow fast changes between tracks, the merge unit 228 should be positioned close to the cutting and creasing station. An empty track 214 may be refilled with cardboard web 204 from a new stack 206 brought to the respective stack position e.g. with a fork lifter or a robot. Fig. 6 shows a cardboard centering guide unit 220. It comprises guide rail mounting elements 264 for the upper guide rails and lower guide rails, side guides 266 for aligning the cardboard web in the transport direction, and bottom lift supports 268 to guide possible hanging front edges upward through the guide unit.

The cardboard web feeder is designed to transport cardboard webs over a long distance reliably to a cardboard web processing machine. For this there is a cooperation between feeding drive unit 202, cardboard centering guide units 220 and support drive units. To allow alignment of the corrugate web with the transport direction also when it is inserted at an angle the main drive rollers 250 of the feeding drive unit are placed to the centerline of the cardboard web. This drive position allows the cardboard web to correct the orientation rather easily without requiring too much force. The first cardboard centering guide unit 220 is placed close to the cardboard feed unit to ensure the cardboard web is correctly aligned with the transport directions. Small deviations in the direction will be corrected here by the side guides 266, where the bottom lift supports 268 ensure that if the leading edge of the cardboard web is bend down at the edges it will be lifted upwards and guided through the cardboard centering guide.

After the first cardboard centering guide, the cardboard transport direction is secured and longer distances between further cardboard centering guides and support drive units can be allowed.

Figure 7 shows a centering guide unit 220' for one track 214 and a support drive unit 234, which are connected by the track 214.

If the distance between the feeding drive unit and the cardboard web processing machine is too large additional support drive units can be included. The support drive units are synchronized with either the cardboard drive or the feeding drive unit, depending on the presence of the cardboard web.

Support drive units are also needed if the cardboard web feeder is placed at a different level than the cardboard web processing machine, e.g. at a floor above the cardboard web processing machine or at a floor below the cardboard web processing machine. If the cardboard web processing machine is placed on a floor below the cardboard web feeder, the support drive unit's primary function is to transport the cardboard web against the feeding direction when the cardboard web is retracted by the cardboard web processing machine, e.g. when the cardboard web processing machine switches between tracks or after each created blank if the cardboard web processing machine uses a cutting on the fly technique.

If the cardboard web processing machine is placed on a floor above the cardboard web feeder the support drive unit’s primary function is to transport the cardboard web against gravity towards the cardboard web processing machine.

Fig. 8 is a schematic perspective view of the entrance portion of a merge unit 228 connected to three tracks, each track being formed by two lower guide rails 218 and two upper guide rail 216, of which only some have been provided with reference numbers.

Fig. 9 is a schematic drawing of a system for packaging items varying in size and number in custom-sized boxes comprising a cardboard web feeder 200 according to the invention in one arrangement. The cardboard feeder 200 is placed on a different level, namely on a floor deck 270 above a box making and packaging system 100' similar to the one shown in Fig. 1 , except for the web feeding unit, which is replaced by the web feeder 200 according to the invention. Often there is a lot of height in logistical warehouses, which means that floor space can be saved when the cardboard web feeders are placed on a different level. In the shown embodiment, some tracks 214, each being indicated in this schematic drawing by a single line although they may each comprise upper and lower guide rails, are led through the floor deck 270 to the system 100'.

Fig. 10 is a schematic drawing of a system for packaging items varying in size and number in custom-sized boxes highly similar to the one shown in Fig. 9. Here, the cardboard web feeder 200 is placed on a level beneath the box making and packaging system 100'. Depending on the particular site, both arrangements shown in Figs 9 and 10 can be beneficial for the logistic flows around the packaging system 100', as the supply of cardboard does no longer conflict with the order supply. The above-mentioned configurations are provided as examples to illustrate possible setups. The solution incorporating additional support drive units offers significant flexibility in the placement of the cardboard web feeders, enabling customized arrangements to suit various operational requirements.

LIST OF REFERENCE NUMBERS

100, 100' packaging system

102 receiving unit

104 cutting and creasing station

106 folding station

108 lid placing station

110 label printing and application unit

112 cardboard web

114 stack of fanfolded cardboard web

116 shipment set

118 shipment set

120 shipment set

122 lid blank

124 corner panel

126 corner panel

128 side panel 128

130 laser scanning unit

132 gripping and folding unit

134 gripping and folding unit

136 glue application unit

138 flap folding unit

140 flap folding unit

142 gluing unit

144 box

146 box

148 guiding stand

150 rotatable element

152 wing axis panel , 200' cardboard web feeder feeding drive unit cardboard web stack of fanfolded cardboard web cardboard web processing machine pallet leading edge track upper guide rail lower guide rail cardboard centering guide unit support beam pile beam merge unit pile beam support drive unit sensor sensor viewing direction viewing direction funnel-like entrance guide plate guide plate drive roller first shaft no-crush rollers second shaft first shaft driven roller guide rail mounting elements guide rail mounting elements side guides bottom lift supports floor deck

Claims

1 . Cardboard web feeder for cardboard web processing machines, in particular for machines for making custom-sized cardboard boxes and/or lids, comprising at least one feeding drive unit adapted to move a cardboard web inserted into it from at least one stack of cardboard in and against a feeding direction, and guide elements defining at least one track for guiding the cardboard web from said at least one feeding drive unit towards a cardboard web processing machine comprising a cardboard drive for moving a cardboard web in and against said feeding direction, wherein said at least one feeding drive unit is adapted for being alternatively controlled dependent on and independent of said cardboard drive.

2. Cardboard web feeder according to claim 1 , wherein said at least one feeding drive unit is adapted for receiving a cardboard web alternatively from at least two separate cardboard stack positions.

3. Cardboard web feeder according to claim 1 or 2, wherein said guide elements define at least two separate tracks for guiding a cardboard web from said at least one feeding drive towards said cardboard web processing machine.

4. Cardboard web feeder according to one of claims 1 to 3, comprising multiple feeding drive units, each feeding drive unit adapted for being alternatively controlled dependent on and independent of said cardboard web processing machine, wherein said guide elements define separate tracks for guiding separate cardboard webs from said multiple feeding drive units towards the cardboard web processing machine.

5. Cardboard web feeder according to claim 3 or 4, further comprising a merging unit for merging at least some of said tracks into a single track.

6. Cardboard web feeder according to one of claims 1 to 5, further comprising at least one support drive unit, said at least one support drive unit arranged along said at least one track and adapted to move a cardboard web in and against a feeding direction along said track, and said least one support drive unit adapted for being alternatively controlled dependent on the cardboard drive and dependent on the feeding drive unit moving a cardboard web in the feeding direction along said one of said track.

7. Cardboard web feeder according to one of claims 1 to 6, further comprising at least one sensor element for detecting the presence of a cardboard web in and/or at the feeding drive unit(s) and/or the support drive unit(s).

8. Cardboard web feeder according to one of claims 1 to 7, further comprising at least one robotic cardboard inserting unit adapted for gripping a leading edge of a cardboard web from a stack of cardboard and inserting it in the at least one feeding drive unit.

9. Cardboard web processing machine, in particular machine for making customsized cardboard boxes and/or lids, comprising structure for cutting and creasing cardboard cut off from a cardboard web to form cardboard blanks, and optionally structure for folding boxes and/or lids from said blanks, characterized by comprising at least one cardboard web feeder according to one of claims 1 to 8.

10. System for automatically packaging items of varying size and number in custom-sized boxes, comprising a box making machine for making custom-sized boxes according to claim 9, further comprising either structure for placing the item(s) to be packaged on a cardboard blank prior to folding it to form a box or structure for placing the item(s) to be packaged in a custom-sized box.

11 . Method for feeding a cardboard web to a cardboard web processing machine, in particular to a machine for making custom-sized cardboard boxes and/or lids, said machine comprising a cardboard drive engaging with a cardboard web to move it in and against a feeding direction, the method comprising employing at least one feeding drive unit engaging with a cardboard web to move it from at least one stack of cardboard in and against a feeding direction along at least one track for guiding a cardboard web from said at least one feeding drive unit towards said cardboard drive, when said cardboard drive is engaged with a cardboard web and said at least one feeding drive unit is engaged with the same cardboard web, controlling said feeding unit dependent on said cardboard drive, and when said cardboard drive is not engaged with a cardboard web, controlling said at least one feeding drive unit independent of said cardboard drive.

12. Method according to claim 11 , comprising, when said cardboard drive is engaged with a cardboard web guided along said at least one of said tracks and said at least one feeding drive unit is engaged with another cardboard web guided along the same track, controlling said feeding unit dependent on said cardboard drive.

13. Method according to claim 11 or 12, further comprising controlling at least one support drive unit, which is arranged along said at least one track and adapted to engage with a cardboard web to move it in and against said feeding direction, such that when said cardboard drive is engaged with a cardboard web and said at least one support drive unit is engaged with the same cardboard web, controlling said at least one support drive unit dependent on said cardboard drive, and when said at least one feeding drive unit is engaged with a cardboard web, while said cardboard drive is not engaged with the same cardboard web, and said at least one support drive unit is engaged with the same cardboard web, controlling said at least one support drive unit dependent on said at least one feeding drive unit.

14. Method according to one of claims 11 to 13, further comprising detecting the presence of a cardboard web in and/or at the at least one feeding drive unit and/or the at least one support drive unit and creating, based on the result of said detecting, at least one of alarm signals and override control signals.

15. Method according to one of claims 11 to 14, wherein controlling said at least one feeding drive unit and said at least one support drive unit dependent on said cardboard drive comprises setting the conveying speed of said at least one feeding drive and/or said at least one support drive unit to about 99 - 95 % of the conveying speed of said cardboard drive, when a cardboard web is moved in said feeding direction, and to about 101 - 105 % of the conveying speed of said cardboard drive, when a cardboard web is moved against said feeding direction.

16. Method according to one of claims 11 to 15, wherein controlling said at least one feeding drive unit and/or said at least one support drive unit dependent on said cardboard drive comprises starting said at least one feeding drive unit and/or said at least one support drive unit about 5 - 50 ms after starting said cardboard drive, when a cardboard web is to be moved in said feeding direction, and about 5 - 50 ms before starting said cardboard drive, when a cardboard web is to be moved against said feeding direction.

17. Method according to one of claims 11 to 16, wherein controlling said at least one feeding drive unit and/or said at least one support drive unit dependent on said cardboard drive comprises when said cardboard drive is started to move a cardboard web in said feeding direction, moving the cardboard web about 5 - 30 mm in said feeding direction with said cardboard drive before starting said at least one feeding drive unit and/or said at least one support drive unit, when a cardboard web is to be moved against said feeding direction, moving said cardboard web about 5 - 30 mm against said feeding direction with said at least one feeding drive unit and/or said at least one support drive unit before starting said cardboard drive.

18. Method according to one of claims 11 to 17, wherein controlling said at least one feeding drive unit independent of said cardboard drive comprises setting the conveying speed of said at least one feeding drive unit to about 5 - 25 % of its maximum conveying speed, when a new cardboard web is inserted into it.

19. Method according to one of claims 11 to 18, further comprising determining the position of the trailing edge of a cardboard web along said at least one track engaged by said cardboard drive and controlling the position of the leading edge of a following cardboard engaged by said at least one feeding drive unit and/or said at least one support drive unit such that said leading edge does not overtake that trailing edge.

20. Method according to one of claims 11 to 19, further comprising determining the positions of the leading edges and the trailing edges of all cardboard webs present in a cardboard web feeder according to one of claims 1 to 10 using at least one of: calculating the position of a trailing edge based on information about the overall length of the respective cardboard web being currently processed and the length of a portion of this cardboard web already processed and the length of the respective track along which said cardboard web is guided to the processing machine, sensor elements along the respective tracks along which cardboard webs are guided to the processing machine, markers on the respective cardboard web and respective counters provided at the feeding drive units, number of turns made by a feeding drive unit and/or a support drive unit comprising drive rollers.

21 . Method according to one of claims 11 to 20, further comprising controlling a plurality of said feeding drive units, each adapted to engage with a cardboard web to move it in and against said feeding direction along one of a plurality of tracks, such that the feeding drive unit engaging with a cardboard web currently processed by said processing machine and travelling along one of said plurality of tracks is controlled dependent on said cardboard drive, and such that at least one remaining feeding drive units is controlled to move a cardboard web along another one of said plurality of tracks to a waiting position close to said processing machine.

22. Method for processing a cardboard web fed from a stack of cardboard into a cardboard web processing machine, in particular a machine for making custom-sized cardboard boxes and/or lids, said method comprising cutting and creasing the cardboard web to form cardboard blanks, and optionally folding boxes and/or lids from said blanks, characterized by employing a method for feeding a cardboard web according to one of claims 11 to 21 .

23. Method for automatically packaging varying shipment sets in custom-sized cardboard boxes, comprising: preparing a shipment set of one or more items to be shipped, calculating the layout of a cardboard box blank for a cardboard box comprising a bottom panel, based on said calculated layout, cutting and creasing a cardboard web fed from a stack of cardboard into a box making machine to form a cardboard blank for a cardboard box for said shipment set, placing the shipment set on said bottom panel prior or after folding a box out of said cardboard blank, characterized by employing a cardboard web feeding method according to one of claims 11 to 21 .