Box erector

A box erector for erecting a box from a knock-down configuration into an open rectangular box is disclosed which includeds a frame (10) for an inventory section (20), a transfer section (22), a flap closure section (24), a taping section (26), and an exit section (28). A transfer arm (A) pivots to a pick-up position where a vacuum assembly (B) picks up a top box and pivots the top box to a box-opening position at approximately 79.degree. from the pick-up position. At the box-opening position, the box is rotated 45.degree. from its horizontal pick-up position, and first and second arms (78, 80) of vacuum assembly (B) open the box to a rectangular shape. Thereafter, the transfer arm moves the box to closure section (22). A drive belt (88) and drive pulleys (88a, 88b) rotate vacuum assembly (B) so that the box is vertically oriented when deposited at flap closure section (24). A pressure foot (92) extends into the box at the closure section and holds the box against the end flaps (29a) and side flaps (31a) as they are closed. The closed flaps are then moved across taping section (26) by horizontal movement of pressure foot (92). The flaps are taped closed, and the box is moved to exit section (28) where it is released upon demand from a product feed line.

BACKGROUND OF THE INVENTION 
The invention relates to a box erector for erecting boxes from a knock-down 
condition. 
Heretofore, box erector apparatus have been proposed for setting up folded 
carton or box planks, closing their bottom flaps, and sealing the bottom 
flaps so that the box may be loaded. For example, see U.S. Pat. Nos. 
4,579,551; 4,348,853; and Re27,631. Pat. No. Re27,631 discloses a box 
erector which utilizes suction for grasping portions of the knock-down 
carton during erection, and various actuators for closing the end and side 
flaps. While apparatus have been previously proposed for automatically 
erecting boxes, they have not been entirely suitable, particularly, as an 
adjoining operation to an existing product line whereby boxes can be 
erected and fed to a feeding system for filling of the boxes with packaged 
products and the like. In addition, the prior box erectors have been 
relatively complicated in construction, and have required a large amount 
of floor space. This has made them particularly unsuitable for utilization 
in existing floor space as an adjunct to an existing product line for 
erecting the boxes to be filled at the product line in conjunction with 
the manufacturing of products. 
Accordingly, an object of the invention is to provide a box erector having 
a small footprint which can be utilized without modification with an 
existing product feeding system. 
Another object of the invention is to provide a compact box erector which 
is simple, yet reliable, and can be utilized as an adjunct to an existing 
product feeding system for boxing of the product. 
Another object of the invention is to provide a box erector which may be 
utilized to erect different size boxes without complicated alteration of 
the erector. 
Another object of the invention is to provide a box erector which erects 
boxes taken from an inventory of boxes stacked in a knock-down condition 
in a simple and reliable manner. 
SUMMARY OF THE INVENTION 
The above objectives are accomplished according to the invention by 
providing an apparatus for erecting a rectangular box from a folded 
knock-down box which requires a small amount of floor space and may be 
displayed adjacent a product feed line to package product in the erected 
boxes in a continuous automatic manner. 
The apparatus includes an inventory section which includes an inventory of 
stacked knock-down boxes with a top box in a pick-up position. A transfer 
section includes transfer means for picking up the top box disposed on top 
of stacked knock-down boxes and transferring the top box to a box-opening 
position. The transfer means includes a box opening means for opening the 
box into an open rectangular box at the box-opening position. A closure 
section receives the rectangular box at a box closure position, and 
includes a flap closure assembly for folding a pair of end and side flaps 
of the box inward for closure. The transfer means transfers the open 
rectangular box from the box-opening position to closure section only 
after the box has been opened. A taping section includes a taping unit for 
securing the end and side flaps in a closed configuration to form a box 
enclosure. An indexing means raises the stack of knock-down boxes a 
prescribed distance each time the transfer means picks up one of the top 
boxes so that a box previously underneath the top box is raised to a 
predetermined pick-up height and becomes a new top box. A release means is 
provided for releasing the indexing means so that platform may be returned 
to a bottom position for reloading of a stack of knock-down boxes. A brake 
means brakes the descent of the platform when lowered to reload position. 
Preferably, the transfer means includes a transfer arm, and a transfer 
drive for rotating the transfer arm through a prescribed angle between the 
box pick-up, box opening, and the box closure positions. The transfer 
drive includes first drive for rotating the transfer arm through a first 
prescribed angle between the box closure and the pick-up positions, and 
for rotating the transfer arm through a second prescribed angle less than 
the first prescribed angle, and in an opposite direction. The transfer 
drive includes a base pivot having a pinion gear affixed to the transfer 
arm and carried by the base pivot. The first drive includes a rack gear 
meshing with the pinion, and a first fluid cylinder having a piston rod 
affixed to the rack gear, and a second fluid cylinder carried by the frame 
having a piston rod on which the first fluid cylinder is carried. Both 
fluid cylinders are actuated to move the transfer arm between the closure 
and pick-up positions. One of the first and second fluid cylinders rotates 
the transfer arm from the pick-up position to the box-opening position, 
and the other of the fluid cylinders rotates the transfer arm from the 
box-opening position to the closure position. The first prescribed angle 
is about 158.degree., and the second prescribed angle is about 45.degree. 
from the pick-up position. A vacuum assembly is carried by the transfer 
arm for picking up one side and an end of the top box. The vacuum assembly 
includes a first arm having suction devices for engaging the side of the 
knock-down box in the pick-up position, and a second, pivotal arm having 
suction devices for engaging the end of the knock-down box in the 
box-opening position. The second pivotal arm includes a pivot having a 
displaceable pivot rod having a first position in which said pivotal arm 
engages the end of the knock-down box, and a second, axially displaced 
position corresponding to engagement with the end when the end is 
perpendicular to side of open rectangular box. The transfer drive includes 
a second drive for rotating the vacuum assembly generally 90.degree. to 
rotate the box horizontally from the pick-up position to an erect vertical 
orientation at the closure position as the transfer arm rotates between 
the pick-up and closure positions. The second drive includes a belt drive 
connected between the base pivot and an end pivot carried near an end of 
the transfer arm which pivotally carries the vacuum assembly. The belt 
drive includes drive pulleys carried by the base pivot and the end pivot 
carry about which an endless belt is carried to provide a desired drive 
ratio to rotate the vacuum assembly generally 90.degree. as the transfer 
arm is rotated substantially more than 90.degree. between the box pick-up 
and closure positions. 
The closure section includes a pressure foot assembly which includes a 
pressure foot and first actuating means for moving the pressure foot 
vertically between a retracted position and a lowered position wherein the 
pressure foot engages an inside bottom of the box in the closure section 
to exert pressure on the box for closure of the end and side flaps. There 
is a second actuating means for moving the pressure foot horizontally from 
the closure section, through the taping section, to an exit section. The 
closure section includes an end flap closure means for closing the end 
flaps of the box, and a side flap closure means for closing the side flaps 
of the box. The end flap closure means includes a movable bar which 
engages the end flaps and fits within a gap defined by adjacent edges of 
the side flaps for holding the end flaps closed while the side flaps are 
being closed upon end flaps. There is a first closure actuating means for 
moving the bar to engage and close end flaps. The side flap closure means 
includes an elongated closure member engaging the side flaps over a 
substantial length of the side flaps. There is a second closure actuating 
means for moving the elongated closure member to engage and close the side 
flaps upon end flaps. The pressure foot then moves the box with closed 
flaps over the taping section where the flaps are taped closed. The box is 
then released from the exit section when the product feed line demands an 
empty box.

DESCRIPTION OF A PREFERRED EMBODIMENT 
Referring now in more detail to the drawings, FIG. 1 is a side view of a 
box erector according to the invention which includes a frame 10 having 
vertical frame elements 12 and various horizontal frame elements 14 
including base frame elements 14a. The box erector has five major 
sections. There is an inventory section 20, a transfer section 22, a flap 
closure section 24, a taping section 26, and an exit section 28. 
Inventory section 20 includes a vertical stack of cardboard boxes 30 
carried on a platform 31 whereby a top box 30a may be picked up from the 
top of the inventory. A ratchet mechanism 32 indexes the inventory to 
maintain a constant height H for each box erection cycle. A height sensor 
valve 34 senses the presence of top box 30a when in a proper position for 
being picked up by a transfer arm assembly, designated generally as A. 
Boxes 30 are held in alignment by an alignment means provided by a 
plurality of guide bars 34. Preferably, there are a pair of guide bars 34 
spaced along the bottom of the box and a single guide bar along the sides 
of the box (FIG. 2). There are no guide bars across a side 10a of frame 10 
since access to the platform needs to be unrestricted for loading of boxes 
from the side. 
As can best be seen in FIGS. 10 and 11, indexing means for raising platform 
31 is provided by a ratchet mechanism 32 which includes a pair of 
overriding clutches 36 and 38 mounted in two separate split housings 40, 
and which rotate on a drive shaft 42. Drive shaft 42 turns a sprocket 44 
that drives a chain 46 which raises and lowers platform 31. For this 
purpose, chain 46 has a first end 46a attached to a flange 48a attached to 
a bearing block 48 which slides on a guide post 50. A second end 46b of 
chain 46 is attached on a rear side to a second flange 48b attached to 
bearing block 48. In this manner, bearing block 48 is raised when a front 
run of chain 46 is lowered. There are a pair of bearing blocks 48 which 
are affixed to platform 31 a diagonal corners, both of which slide on a 
vertical slide post 50. Sprocket 44 moves inventory platform 31 up in 
precise increments under the action of the overriding clutches 36 and 38. 
Overriding clutch 36 acts as a lock in allowing shaft 42 to rotate only in 
a clockwise direction. Overriding clutch 38 acts as a driver in rotating 
shaft 42. Each split clutch housing 40 includes a first clutch housing arm 
40a and a second clutch housing arm 40b. The clutch housing and clutch 
arms are split at 40c. A ratchet housing 52 rotatably supports shaft 42 
and the overriding clutches together with split clutch housings 40. A 
double actuating air cylinder 54 is affixed to a bottom part of ratchet 
housing 52 at a pivot 52a. Air cylinder 54 includes a piston rod 54a 
attached to clutch housing arm 40a of drive clutch 38 at a clevis 54b. 
Cylinder 54 rotates clutch housing arm 40a as piston rod 54a extends to 
rotate shaft 42 counterclockwise through clutch 38 (as viewed in FIGS. 
10-12). Clutch arm 40a of locking clutch 36 is affixed to a side of 
ratchet housing 42 by a bolt 42a so that locking clutch 36 prevents shaft 
42 from rotating in an opposite direction between drive strokes of piston 
54a and clutch 38. Each of the split clutch housings 40 has a toggle 
linkage lock 56 which clamps the split clutch housing arms 40a and 40b 
together in a press fit so that they move as one piece. Toggle linkage 
lock 56 includes linkage 56 which pivots about a pivot 56a attached to arm 
40a, as can best be seen in FIG. 11. There is a lock pin 56b carried by 
housing arm 40b. Movement of the linkage 56 to a vertical position, as 
shown, causes arms 40a and 40b to be forced towards another by action of 
tapered V-groove 56c formed in linkage 56. This causes the split 40c and 
split housing 40 to close whereupon clutch 38 is driven by movement of arm 
40a, and clutch 36 free wheels. On the down stroke of piston 54a, clutch 
38 free wheels and clutch 36 holds shaft 42 against rotation. For purposes 
of engaging and disengaging the toggle linkage lock, there is a knob 56d 
carried atop each linkage. Thus, clutch 36 provides a latch means which 
latches the indexing means and platform 31 at box pick-up height H. Means 
for releasing the latch means provided by clutch 36 is provided by 
releasable toggle linkages 56 which allow platform 31 to descend for 
reloading of boxes. During descent, brake means for braking the descent 
will be provided by cable cylinder 58. This allows normal ratcheting 
action by the ratchet mechanism and lifting of the inventory platform in 
precise increments. Releasing the toggle linkage lock allows expansion of 
a hole diameter 56a, thus freeing the clutch within the housing so it can 
now rotate in an opposite direction against which the clutch had been 
previously locked so that the inventory platform may be lowered. Clutch 38 
drives shaft 42 in rotation to advance sprocket 44 and inventory platform 
30 in a precise increment. Overriding clutch 36 is installed on shaft 40 
to clutch an opposite rotational direction so that it free-wheels about 
shaft 42 as shaft 42 is rotated by engaged clutch 38. As piston rod 54a is 
retracted, clutch 38 will free-wheel while clutch 36 will engage so that 
shaft 42 does not rotate in an opposite direction, but is locked at that 
platform height. This maintains the height of inventory platform 30 to 
which it was lifted by the extension of piston rod 54a. Clutches 36 and 38 
may be any suitable clutches such as a roller bearing clutch manufactured 
by Torrington Company of Torrington, Conn., as dc overriding clutches. 
Thus, it can be seen that ratched mechanism 32 allows inventory platform 
31 to be raised in increments to maintain the correct inventory height H 
and when released the clutch override permits lowering the platform. 
Height sensor 34 is preset to operate at the correct inventory height and 
shuts off operation of cylinder 54 in preventing over-shoot of the 
inventory height. A cable cylinder 58 is attached to inventory platform 31 
which serves as a break when toggle linkage lock 56 on clutches 36 and 38 
is released. A throttle valve adjusts the maximum speed of the downward 
motion of the inventory. Cable cylinder 58 may be any suitable cable 
cylinder such as one manufactured by the Tol-O-Matic Corporation of 
Minneapolis, Minn. A carton keeper 60 is carried by frame 10 and prevents 
misalignment of boxes 30 as transfer arm A returns to a pick-up position 
allowing contact of vacuum cups with the cartons. 
Referring now to transfer section 22, transfer means for picking up a 
carton from inventory, opening the carton, and placing and holding the 
carton in closure section 24 will now be described. As can best be seen in 
FIGS. 3 and 4, there is a transfer arm assembly A having a base 62 carried 
by frame 10 and an end pivot 64. There is a base pivot 66 carried by base 
62 about which an arm 61 of transfer arm assembly A pivots by a drive 
means which includes a rack 68 and a pinion gear 70. There is a pair of 
cylinders 72 and 74 which drive rack 68 in a linear motion which rotates 
pinion gear 70 that is bolted onto arm 61. End pivot 64 provides the 
pivotal and mounting point for a vacuum assembly, designated generally as 
B, which includes a plurality of vacuum cups 76. Vacuum assembly B 
includes a first vacuum pick-up arm 78 and a second box opening arm 80 
carried by a bracket 65 which is affixed to pivot shaft 64. Pick-up arm 78 
includes a plurality of vacuum cups 76, and opening arm 80 includes a 
plurality of vacuum cups 76a. Box opening arm 80 pivots about a pivot 88 
carried by brackets 65 and includes an axially displaceable pivot rod 80b 
which slides within bracket 81 that is affixed to a piston rod 84a of 
cylinder 84. Box opening arm 80 pivots inwardly to engage an end 29 of box 
30. Because of the box thickness when the ends and sides are knocked down, 
as illustrated in FIG. 4, it is necessary to spring-load displaceable 
pivot rod 80b so that when the box opening arm pivots 90.degree., as shown 
in full lines in FIG. 4, the suction cup is not disturbed in its position 
on the end 29 of box 30. If the pivot arm did not change its length, the 
suction cup would be pulled inwardly upon the outward pivoting of box 
opening arm 80 causing the cup to lose its suction. For this purpose, 
there is a tension spring 80c which retracts pivot rod 80b and allows it 
to move outwardly during pivoting. A vacuum is applied to the suction cups 
through conventional fittings 82 from a vacuum source (not shown). With 
transfer arm A at a pick-up position, as shown in dotted lines in FIG. 1, 
vacuum cups 76 of pick-up arm 78 make contact with a top carton 30a. 
Carton height sensor valve 34 is set to insure each carton reaches this. 
When a vacuum is applied to vacuum cups 76, a vacuum is applied to the 
carton. A vacuum sensor 82a is preset to insure proper grip is maintained 
during this transfer and a second vacuum sensor 82 provides the same 
action as the carton end is pulled open by opening arm 80. If either of 
these sensors sense a vacuum loss during transfer and opening, the machine 
can be placed on hold for operator assistance. When vacuum sensor 82 
senses a vacuum condition, cylinder 72 is extended fully. Cylinders 72 and 
74 are double actuating air cylinders. Reaching extension allows cylinder 
74 to extend which swings opening arm 80 and vacuum cup 76a onto an end 29 
of the box. Vacuum sensor 82a now senses a preset vacuum on vacuum cup 76a 
which allows cylinder 84 to retract pulling out the carton side and ends 
forming a square box shape. Cylinder 84 may be any conventional double 
acting cylinder. At this point, a sensor 86 senses the presence of an 
operator 86a to let the system know cylinder 84 has retracted. The 
retraction signal from sensor 86 and vacuum sensor signal from 82a may be 
used to signal extension of cylinder 74 which moves rack 68 further 
upwards pivoting the opened box into closure section 24. Cable 88 is 
connected to pivot points 64 and 66 of pivot arm A to provide proper 
timing of rotation of the box from a horizontal to a vertical position for 
flap closure. The transfer drive means for driving transfer arm A includes 
a first drive means provided by rack 68 and pinion gear 70 as actuated by 
cylinders 72 and 74. This rotates arm A approximately 158.degree. the box 
pick-up position, as shown in FIG. 1, to the box closure position wherein 
the box is vertically disposed at closure section 22. Intermediate the 
pick-up position and box closure position is the box-opening position 
which is approximately 79.degree. counter-clockwise from the pick-up 
position. Transfer drive means includes a second drive which rotates 
vacuum assembly B as transfer arm A rotates from the pick-up position to 
the box closure position. The second drive rotates vacuum assembly 
generally 90.degree. so that the box is rotated horizontally from the 
pick-up position to an erect vertical configuration at the closure 
position at closure section 22. Preferably, the second drive means 
includes a belt drive provided by belt 88 which encircles a drive pulley 
88a affixed to pivot shaft 64 and a drive pulley 88b affixed to pivot 
shaft 66. Drive pulleys 88a and 88b provide a prescribed drive ratio so 
that vacuum assembly B rotates generally 45.degree. from the pick-up 
position to the box-opening position, and 45.degree. from the box-opening 
position to the box closure position, as arm A travels 158.degree.. 
Cylinder 72 is affixed to vertical frame leg 12. Cylinder 74 is affixed to 
piston rod 72a of cylinder 72. Piston rod 74a of cylinder 74 is attached 
to rack 68. Cylinders 72 and 74 provide the motion to rotate transfer arm 
A in two steps. First, cylinder 72 rotates the transfer arm approximately 
79.degree. from the pick-up position which allows room for end opening 
cylinder 84 to open the box into a square or rectangular form. At the same 
time, the top box is rotated 45.degree. during travel to the box-opening 
position. If vacuum is lost in this function of operation, the machine 
will not proceed to the next sequence. Second, cylinder 74 extends only 
when the box-end opening cylinder 84 has retracted. 
Referring now to closure section 24, the closure section is sequenced to 
close end flaps 29a and then side flaps 31a of the ends and sides, 
respectively, of the box. When transfer arm A positions box 30 into 
closure section 34, a tape cylinder 90 is actuated to extend a pressure 
foot assembly, designated generally as C, over the box. Tape cylinder 90 
is preferably a conventional band cylinder which is available from the 
Tol-O-Matic Corporation. Pressure foot assembly C includes a pressure foot 
92, a pressure foot cylinder 94, and a retraction and extension mechanism, 
designated generally as 96. Mechanism 96 includes meshing gears 96a and 
linkage arms 96b actuated through the gears. Cylinder 94 may be any 
suitable conventional double actuating air cylinder. Upon extension of 
tape cylinder 90 to a left-most position, as can best be seen in FIG. 5, a 
sensor 98 is engaged and activated which may be used as a signal to 
activate pressure foot cylinder 94. Actuation of pressure foot cylinder 94 
extends pressure foot 92 into the open box, as can best be seen in FIGS. 
5-7. The pressure foot stabilizes the box during flap closure. When the 
pressure foot is extended into a box, end flap cylinders 100 are actuated 
which closes end flaps 29a. Piston rod 94a has an end connected to 
extension/retraction mechanism 96 at a pivot 94b. When pressure foot 92 is 
extended into an open box, pivot end 94b is retracted to the left. This 
position may be sensed by a sensor 102. The signal from sensor 102 may be 
utilized to actuate cylinders 100 to close end flaps 29a. For this 
purpose, cylinders 100 include piston rods 100a attached to a clevis 100b 
that is attached to a pivot rod 102 to which is affixed a closure rod 102a 
which provide an end flap closure means. Extension of cylinders 100 causes 
rod 102a to pivot counter-clockwise and engage end flaps 29a raising them 
to a horizontal position, as can best be seen in FIG. 6. Cylinders 100 may 
be any conventional double actuating air cylinder. A sensor 104 and 
operator 104a may be utilized to sense extension of cylinders 100, as can 
best be seen in FIG. 2. 
The signal from sensor 104 may be utilized to actuate a side flap closure 
means which includes a pair of cylinders 106 which pivot arms 108 that 
carry side plates 110 which extend across the width of side flaps 31a, as 
can best be seen in FIG. 7. It is to be appreciated that closure bars 102a 
are provided in the form of a simple narrow bar while closure plates 110 
are provided having a width about the same as the width of side flaps 31a. 
This provides the expedient that end flap bars 102a may be accommodated 
between the opposing edges of side flaps 31a to hold end flaps 29a 
horizontal while side flaps 31a are being closed by cylinders 106, as can 
best be seen in FIG. 7. A stationary sensor 112 and a movable operator 
112a carried by a pivot shaft 108a provide a signal to indicate the side 
flaps have been closed (FIG. 2). The side flap closure signal may be used 
to actuate tape cylinder 98 to retract the cylinder moving pressure foot 
assembly C and box 30 to the right, as can best be seen in FIG. 5. As box 
30 moves to the right, it moves across tape section 26. 
As can best be seen in FIG. 2, tape section 26 includes tape applicator 
120, side squeeze rolls 122, and idler rolls 124. Pressure foot 92 
extended into the open box, within its side flaps closed, the pressure 
foot moves the box, with pressure applied to the bottom flaps, over tape 
applicator 120. Before the box strikes the tape applied by tape applicator 
120, squeeze rollers 122 force the bottom flaps together which eliminates 
the gap between the two side flaps to insure a tight seal of the bottom. 
Side squeeze rollers 122 also act as a centering guide for the box as tape 
is applied to the box. As tape cylinder 90 reaches its home position, 
which is retracted to the right, a sensor 126 is actuated which causes 
pressure foot cylinder 94 to retract pressure foot 92 from the box. Tape 
section 26 may include a conventional taper unit manufactured by 
Customized Equipment Southeast, Inc. of Tucker, Ga. 
Referring now to exit section 28, a sensor 130 may be utilized to sense the 
retracted position of pressure foot 92, as can best be seen in FIG. 9. In 
the exit section, the box is positioned so that it can be indexed into a 
feed system to receive a product. Exit section 24 includes an exit 
cylinder 132 which pushes box 30 into drop hinges 134 which provide a box 
release means. For this purpose, exit cylinder 132 includes a generally 
L-shaped arm 132a carried by the cylinder which pushes box 30 to the side 
over drop hinges 134 when exit cylinder 132 is extended. Drop hinges 134 
allow the box to drop only when space is available on the feed system 
below. Space availability may be sensed by a sensor valve (not shown) on 
the customers feed system which can be utilized to actuate a pair of drop 
cylinders 136 which actuate the drop hinges 134. A pair of top flap 
cylinders 140 may be provided to break the crease of the top flaps so that 
they may be more easily closed at a subsequent step. After box 30 is 
dropped by drop hinges 134, a new box erection cycle will begin 
automatically and continue until the inventory of unfolded boxes is 
depleted which shuts the machine down. A sensor 142 may sense box 30 as it 
is dropped to a position. A sensor 144 may be utilized to sense the 
position of inventory platform 30 when it is empty. In this manner, signal 
from sensor 142 may be utilized to start a new box erection cycle and a 
signal from sensor 144 may be utilized to shut the machine down. 
Preferably, the air cylinders in operation described above are done 
pneumatically. The sensors which have been described may be any suitable 
air valves such as three-way or four-way air control valves manufactured 
by Humphrey Products Company of Kalamazoo, Mich. Suitable air cylinders 
are manufactured by the Compact Air Products Corporation of Westminster, 
S.C., and suitable vacuum cups, sensors, and generators, are available 
from Vaccon Corporation of Norwood, Mass. The arrangement of a suitable 
pneumatic control circuit including switches, valves, and pneumatic hoses, 
is within the purview of one skilled on the pneumatic control art and 
having been taught the operation and advantages of the present invention. 
While a preferred embodiment of the invention has been described using 
specific terms, such description is for illustrative purposes only, and it 
is to be understood that changes and variations may be made without 
departing from the spirit or scope of the following claims.