The present invention provides a denesting apparatus (100, 200), the apparatus comprising: ⋅—one or more closed loop conveying tracks (130, 230), each closed loop conveying track comprising a plurality of sets of one or more de-stacking means (140, 240) movingly configured thereon through one or more de-stacking means moving mechanism (150, 250); ⋅—one or more stacking magazines (120, 220), each adapted to hold a stack of sheets (110, 210) supported thereon; wherein each of the plurality of sets of de-stacking means is adapted to selectively engage an uppermost sheet from at least one of the stacking magazines in any desired order either sequentially and/or simultaneously so as to discharge the picked-up sheets onto an out-feed conveyor (180, 280) in any desired manner either one besides another or otherwise one overlapping the other.

TECHNICAL FIELD

The present invention relates generally to a denesting apparatus for denesting one or more stacks of sheets.

BACKGROUND

In the recent years, there has been a many-fold increase in the trend of grouping large number of items such as food items, including liquid foods, home essentials, stationary items, beverage containers, and the like, in the form of secondary packages, for various purposes such as to enable bulk selling, easy transportation, handling, and the like.

Recently there has been a considerable increase in use of cardboard based packaging for holding liquid foods and beverages which resulted in an increase in the manufacture of cardboard packaging or cartons in a variety of shapes and sizes.

Cardboard based packaging is generally formed of foldable blank or sheets, received generally in one or more stacks and therefore, during the packaging manufacturing process, it is required to sequentially and individually de-stack or unstack these blanks or sheets from the stacks thereof which are then fed on to a packing process for formation of various kinds of packaging.

Conventionally, the step of de-stacking these blanks or sheets has been performed by utilizing various kind of pickers such as for example, manipulators, which may also take the form of robots and/or robotic arms, adapted to pick up a top sheet from the stack intermittently. Unfortunately, such pickers are often not cost-efficient and have a high turn-around time and therefore do not reconcile well at instances where a continuous in-feed of these sheets at a high speed is required.

Accordingly, numerous efforts have been imparted to produce tools that de-stack sheets from the stacks individually, sequentially and at a high speed. Examples include various mechanical assemblies including so called fingers and/or grippers adapted to lift and/or pull away either the uppermost or lowermost sheet from the stack. However, these fingers and grippers based pulling mechanisms were generally adapted to pull either a fixed size sheet or at least having similar shape and/or size convenient to be handled by such fingers or grippers. Additionally, such devices may result in high rates of rejection since the sliding contact of these pulling devices frequently damages the sheets.

While it is usually desirable to provide a system which de-stacks sheets of material as quickly as possible, it is also important that the same de-stacking apparatus may be utilized for a variety of shapes and sizes of sheets. To overcome the problems of mechanical assemblies, various kind of air-nozzle based de-stacking mechanisms were introduced.

For example, WO2008015347 discloses the use of a retractable blower member disposed generally perpendicularly to a stack of sheets so as to blow a jet of air onto the flat items thereby removing the top sheet from the stack thereof.

Similarly, US20110229297 discloses a denesting apparatus having a product carrier plate including a pair of air nozzle assemblies operable to separate a tray from the stack of trays and force the tray against the product carrier plate such that movement of the product carrier plate can selectively discharge the separated tray.

However, these air nozzle-based side blowing mechanisms are generally not effective in un-stacking sheets having different thickness. Further, in most instances, these de-stacking mechanisms uncontrollably dislodged more than one sheet, which is not acceptable particularly in an automated system.

Therefore, various other solutions were tried out to denest the top sheet from stacks thereof. Recently, the trend has been shifting towards use of a variety of suction mechanisms for performing the denesting operation. These mechanisms generally utilize suction mechanisms either singly or in conjunction with air nozzles.

For example, EP1541508 discloses a device for the de-stacking of flat objects laid on a stack. The device has a suction device located above the stack support, and a pushing away device with pushing components. The suction device and pushing away device are located at a fixed distance above the stack support, and the pushing components on their end face facing the stack support during the pushing away of an object from the suction head of the suction device have a stop for the next object lifted from the stack by the suction head. U.S. Pat. No. 3,401,831 discloses a denester which, in addition to the suction grippers, includes nozzles which blow pressurized air between the outermost tray and the tray immediately succeeding it, in order to facilitate their separation. Such suction mechanism utilizes suction heads/nozzles which further requires vacuum hoists/supply to create negative air pressure for suction. Therefore, these arrangements are often overly complex in design, and were also undesirably slow in their operation.

Recently, various kind of de-stacking means or cups-based mechanisms have been utilized due to their simple structure and designs. For example, as disclosed in U.S. Pat. No. 5,254,071, these mechanisms generally include a drive mechanism with a vacuum cup which is alternatively brought close, put into contact then moved away from the stack of sheets. The vacuum cup is laid against the top sheet of the stack and then carries away the top sheet to bring it away from the stack before laying it down on another work area, for example, on a packaging line conveyor.

In some other variations, de-stacking means were utilized to pick the sheet/tray from bottom as described in US20140056684 which discloses a tray denesting apparatus presenting stacks of trays placed upside down within a storage area to a picker mechanism and separating single trays from the stack of trays. A de-stacking means is used to remove individual trays from the tray stack. After picking up the individual tray, a driven rotary device inverts the tray and places the tray onto a tray conveyor located beneath the denesting apparatus.

However, all such packaging apparatuses have certain shortcomings as well. Firstly, these de-stacking means based mechanisms utilize drive mechanisms adapted to pick up and denest the sheets in accordance to a predetermined distance setting from a predetermined stack. Such system is, however, not designed for cases where a same packaging is a combination of different kind of sheets, such as e.g. a package blank combined with a partition blank.

Accordingly, as can be understood from the foregoing discussion, none of the existing solutions completely provides flexibility of varying the de-stacking operation in accordance to varying requirements of multiple stacks simultaneously while preventing suspending the operation. Thus, in the context of the above, it is desirable to provide a denesting device that overcomes these problems associated with the prior art, is affordable, and allows to carry out de-stacking of multiple stacks of different packaging material blanks or sheets of varying configurations, size, shape, material and caliper in the desired manner, without requiring to change functional elements thereof.

SUMMARY

In one aspect of the invention, a denesting apparatus for denesting sheets of foldable blanks from one or more stacks thereof is provided. The denesting tool includes one or more closed loop conveying tracks comprising a plurality of sets of de-stacking means movingly configured thereon through a de-stacking means moving mechanism. The denesting apparatus further includes one or more stacking magazines each adapted to hold one or more stacks of sheets to be denested. In operation, each of the plurality of sets of de-stacking means is adapted to selectively engage an uppermost sheet from at least one of the stacking magazines and discharge it onto an out-feed conveyor. The picking up of the sheets from the one or more stacks may be performed in various desired order either sequentially or otherwise simultaneously so as to discharge the picked-up sheets in any desired manner either one besides another or in an overlapping manner i.e. one over the other.

Generally, the de-stacking means of attachment to the packaging material sheet or blank, may be a conventionally known suction cup and/or vacuum cup having a generally bell-shaped structure and formed of a generally soft material such as a rubber, silicon, and the like, that is impenetrable by air, or may be any of a number or means of temporarily attaching (holding on to) an article including methods of pin, clamping, magnetic, static electric, Van Der Waals force, Bernoulli contactless suction, to name a few.

Optionally, the de-stacking means moving mechanism includes a plurality of de-stacking lugs, each adapted to movingly engage one of the sets of one or more de-stacking means through an engagement means.

Further optionally, each of the de-stacking lugs is movingly configured onto one of the closed loop conveying tracks through one or more de-stacking movers movingly configured thereon.

In a specific embodiment, the denesting apparatus comprises one, or two or more, generally parallel closed loop conveying tracks which are horizontally adjustable in pitch and in absolute position relative to the machine datum and wherein the de-stacking means moving mechanism includes a plurality of de-stacking lugs movingly configured onto the parallel closed loop conveying tracks through one or more de-stacking movers movingly configured thereon and wherein the de-stacking movers on the parallel closed loop conveying tracks are independently controlled to achieve controlled elevation or loweration whilst in translation of the picked-up sheet.

Possibly, the engagement means may be any conventionally known mechanism suitable for supporting one or more de-stacking means onto the de-stacking lugs and is selected from one or more of, but not limited to, a supporting plate. Alternatively, the engagement means includes an articulating engagement assembly to movingly engage one of the sets of one or more de-stacking means onto the one or more de-stacking lugs, and adapted to provide generally a perpendicular and/or transversal movement along with a longitudinal movement, enabling a picking up a sheet from one of the stacking magazines.

Possibly, the articulating engagement assembly includes an articulated bracket having a first end connected to a first de-stacking mover through a first de-stacking lug, a second open end connected to a second de-stacking mover through a second de-stacking lug and a pivotally movable center end connected to a supporting plate having one or more de-stacking means configured thereon, such that a longitudinal movement of the de-stacking movers towards and/or away from each other enables a generally perpendicular movement to the supporting plate and in turn to the one or more de-stacking means so as to pick up a sheet positioned at a distance thereto. So by changing the relative distance between the first and second de-stacking movers, the position of the de-stacking means relative to the uppermost sheet to be picked-up (i.e. so-called picking plane) may be adjusted.

In another embodiment, possibly, the articulating engagement assembly includes an articulated bracket having a first end connected to a first de-stacking mover through a first de-stacking lug, a second end connected to a second de-stacking mover through a second de-stacking lug and third end connected to a third de-stacking mover through a third de-stacking lug and a pivotally movable center end connected to a supporting plate having one or more de-stacking means configured thereon, such that a longitudinal movement of the de-stacking movers towards and/or away from each other enables a generally perpendicular movement to the supporting plate and also control of the angle of approach, contact and translation of the supporting plat and picking means with the picking plane of the destacking mechanism, so as with the additional degree of freedom to optimize the contact, attach and accelerate away with the packaging material blank there so picked.

Further possibly the supporting plate is a generally horizontally rotatable plate facilitating rotation of the sheet picked up by the one or more de-stacking means.

In an embodiment of the present invention, the de-stacking means movement mechanism may be adapted for moving the de-stacking means horizontally upon picking the uppermost sheet before lifting it. The horizontal movement before lifting tending to fly the sheet off the following and tending to establish an air gap thus enhancing the separation of the sheets.

In a particular embodiment in accordance with the present invention, the denesting apparatus may further comprise a means for forcing the underside of a picked-up sheet against a means for applying friction in reverse direction relative to conveying direction onto the underside of the uppermost sheet. The means for forcing may be an air blower blowing on the top side of the picked sheet that the underside of the sheet is cause to bear up against a means for applying friction such as a reverse spinning wheel or belt. By forcing the underside of the picked sheet against a means for applying reverse acting friction, any tendency for one or more sheets to follow the picked-up sheet is counter-acted such that any duplicated sheets are pushed back into the enclosure of the magazine.

In another embodiment, the denesting apparatus comprises two of said closed loop conveying tracks in parallel and a movement mechanism for varying the distance between said two parallel tracks and their position relative to the datum of the machine, thereby enabling to pick sheets of various size and enabling where on the different sized and shaped sheet to attach during the picking operation.

Optionally, the one or more stacking magazine is a vertically movable supporting rack adapted to move between a top position PTand a bottom position PBusing a vertical movement mechanism.

Further optionally, the vertical movement comprising a vertical rail comprising one or more stacking movers movingly configured thereon and each of the stacking movers engaging the supporting rack using a connecting member such that the stacking member is movable between the top position PTand the bottom position PBthrough the stacking movers.

Alternatively, the vertical movement mechanism may be any suitable movement mechanism.

Possibly, the top position PTof the stacking magazine is positioned at a height HTaway from a base platform, corresponding to the base position PB, such that a top sheet of the stack is positioned at a height HSsuitable to be picked up by at least one of set of the de-stacking means.

Generally, the denesting apparatus further includes a retractable lifting means positioned over the one or more stacking magazine and adapted to support at least a sub-stack of sheets such that the top sheet of the corresponding sub-stack is positioned at the height HSsuitable to be picked up by at least one of the de-stacking means.

Further, the retractable lifting means is adapted to be vertically movable such that after removal of the top sheet, the next top sheet is always positioned at the height HSsuitable to be picked up by the one or more de-stacking means.

Furthermore, the retractable lifting means is configured to retract back and move back to its base position, once each of the sheets supported thereon is picked up by the one or more de-stacking means.

Additionally, the retractable lifting means is further configured to open and pick up another sub-stack of the sheets at its base position.

Possibly, the apparatus further includes an infeed conveying line connected to the one or more stacks such that as soon as an empty magazine is received at its bottom position, it gets replenished with new stack of sheets.

Optionally, the stacking magazine may be a horizontally moving conveyor.

Optionally, the one or more closed loop conveying tracks, the lifting plate, and the one or more stacking magazines are adapted to move at a predetermined pitch so as to denest the stacks of the one or more sheets onto the out-feed conveyor continuously.

Alternatively, the one or more closed loop conveying tracks, the lifting plate, and the one or more stacking magazines are adapted to move intermittently at a variable pitch as required, so as to denest the stacks of the one or more sheets onto the out-feed conveyor intermittently.

Preferably, the vertical movement of the stacking magazine is configured in such a way that when the lifting plate is in its retracted position, the stacking magazine is in its top position such that the top sheet is positioned at the height HSsuitable to be picked up by the one or more de-stacking means.

Optionally, the denesting apparatus includes a first powering means enabling a movement of each of the one or more closed loop conveying tracks, the infeed conveyor, the retractable lifting means, the stacking magazine and the out-feed conveyor.

Further optionally, the first powering means may be selected from one or more of but not limited to various conventionally known linear motors, asynchronic motors, machines, servo drives, and the like conventionally known in the art.

Possibly, each of the plurality of movers on the closed loop conveying tracks is individually powered by a second powering means, preferably a linear motor, utilizing each of the movers as a rotor thereof and the corresponding track as a stator thereof. Alternatively, any other type of driving means adapted to propel the movers in an independent and controlled way may be used.

Alternatively, the second powering means may be selected from one or more of, but not limited to, various conventionally known asynchronic motors, machines, servo drives, and the like, conventionally known in the art.

In addition, the de-stacking means and the de-stacking moving mechanism may be wirelessly powered, for example via sliding contacts on the de-stacking movers, and preferably contactless powered, for example by providing inductive power to the de-stacking movers. Further, the de-stacking means and its moving mechanism may be wirelessly controlled, including but not limited to short range wireless, such as Bluetooth, Infrared, Micorwave, WLAN, narrow through broadband telecommunication and the like, preferably in combination with wirelessly powering. Wireless machine control and contactless power supplies enable highly flexible, large range, untethered movement and motion controlled operation of the recirculating de-stacking means to achieve efficient denesting operations.

Particularly, the sheet of foldable blank is formed of a material selected from one or more of, but not limited to paperboard, corrugated board, thermoplastic, hybrid material, laminated board and the like.

Possibly, the denesting apparatus further comprises a control unit for optimizing the movement of the one or more closed loop conveying tracks, the one or more de-stacking means, the one or more stacking magazines, the retractable lifting means, and the incoming conveying line.

Further possibly, the control unit includes one or more sensors, one or more input units, a processor unit and an output unit.

In a particular embodiment, the apparatus may comprise one or more sensors enabling real-time, inline measurement of the distance between the de-stacking means and the uppermost sheet of a magazine to be picked up and a control unit to dynamically control and adjust the position and reach of the de-stacking means for optimum performances.

In further particular embodiment in accordance with the present invention, the denesting apparatus may comprise two closed loop conveying tracks, and one or more sensors may measure the position of the picked-up sheet, preferably of its leading edges, while moving it onto the out-feed conveyor, and a control unit may control and adjust the position of the de-stacking movers of the respective closed loop conveying tracks relative to each other to correct any angular and/or translational mis-alignment of the picked-up sheet.

The denesting apparatus may comprise two one or more sensors enabling real-time, inline measurement of the angular and position alignment of any picked sheet or packaging material blank and a control units to dynamically adjust the relative positions of the mover mounted denesting mechanisms opposite each other between the generally parallel closed loop tracks, or controlled rotation of the denesting mechanism, to dynamically correct any angular or translational error.

Further, de denesting apparatus may comprise one or more sensors enabling real-time, inline detection of a double or more sheet pick and the activation of means of pressing the picked sheet against the said reverse acting friction device to counter the multi-sheet pick and return the excess to the stacking magazine. The sensor would also enable detection of any no-pick, invoking appropriate remedial action within the overall product loading functions of the machine.

In yet another aspect of the invention, a method of denesting one or more stacks of sheets, each supported onto a corresponding stacking magazine, using the denesting apparatus of the present invention, is provided. The method includes receiving one or more stacks of sheets of a predetermined material. The method further includes picking up a top sheet from the one or more stacks in a predetermined manner either sequentially or otherwise simultaneously. The method further includes placing the picked-up sheet onto the out-feed conveyor in any desired manner, either one besides the other or otherwise one over the other.

Optionally, the method includes rotating the picked-up sheet before placing it onto the out-feed conveyor.

Optionally, the method includes forming, folding, stretching or otherwise shaping the picked-up sheet before placing it onto the out-feed conveyor or, merging or assembling it with another packaging material already picked within the Denesting System.

Optionally, the step of picking up the one or more sheets from the one or more stack includes the step of contacting at least the one or more de-stacking means, with one of the stacks such that the top sheet of the stack is picked up by the corresponding de-stacking means.

Optionally, the method includes picking one sheet at a time sequentially.

Alternatively, the method includes picking more than one sheet at a time simultaneously.

Further alternatively, the method includes dropping the simultaneously picked up sheet either simultaneously one besides other or otherwise sequentially one over the other.

Possibly, the method includes moving the each of the one or more or more pair of de-stacking lugs together in a predetermined sequence of vertical movement and/or transversal movement and/or longitudinal movement, so as to position the corresponding de-stacking means in contact with the top sheet of the desired stack of sheet.

Further possibly, the pushing sequence is determined by the control unit on the basis of an input from a user and/or input from one or more sensors.

Other aspects, features and advantages of the subject matter disclosed herein will be apparent from the description, the drawings, and the claims.

DETAILED DESCRIPTION

The present application discloses a denesting apparatus, for picking up sheets individually from one or more stacks in any desired order and discharging them onto an out-feed conveyor in any desired manner. The denesting apparatus while being efficient, is able to de-stack sheets from multiple stacks having sheets of different shapes, sizes, material and caliper (thickness) without requiring any changes in the functional elements thereof. Further, the sheets may be picked up either simultaneously or otherwise sequentially and may be dynamically discharged in a synchronized manner, on to an out-feed conveyor, with the sheets placed either one besides another or otherwise one over another, either continuously or otherwise intermittently and in varying configurations, speeds, and the like, without making any physical change within the apparatus.

As illustrated inFIG. 1, the present invention provides a denesting apparatus100for de-stacking one or more stacks of sheets110individually and delivering them in a synchronized fashion onto attachment means (not shown) of an out-feed conveyor180.

The denesting apparatus100includes one or more overhead closed loop conveying tracks130comprising a plurality of sets of de-stacking means140movingly configured thereon, through a de-stacking means moving mechanism150. The denesting apparatus100further includes one or more stacking magazines120, each adapted to support one of the one or more stacks of sheets110. Further, each of the stacking magazines120is connected to an incoming conveying line (not shown) carrying a supply of stacks of sheets110. The denesting apparatus100furthermore includes a retractable lifting mechanism160adapted to support at least a sub-stack of the stack of sheets110such that a top sheet is positioned at a height suitable to be picked up by at least one of the sets of de-stacking means140. In operation, the one or more stacks of sheets110are first positioned onto the one or more stacking magazines120. Thereafter, one or more sets of the de-stacking means140is movingly positioned towards the one of the one or more stacks110such that the top sheet from at least one of the stacking magazines120is picked up in any desired order, and discharged towards the out-feed conveyor180in any desired manner.

In description of theFIG. 2that follow, elements common to the schematic system will have the same number designation unless otherwise noted. In a first preferred embodiment, as illustrated inFIG. 2, an exemplary denesting apparatus200having a single closed loop conveying track230for denesting one or more stacks of sheets210, including a first stack210apositioned onto a first stacking magazine220a, and a second stack210bpositioned onto a second stacking magazine120b, onto an out-feed conveyor280.

The closed loop conveying track230includes a plurality of sets of one or more de-stacking means240movingly configured thereon through a de-stacking means moving mechanism250. The de-stacking means moving mechanism250includes a plurality of de-stacking lugs252(FIGS. 5A, 5b), each movingly configured onto the closed loop conveying track230through a de-stacking mover254(FIGS. 4A, 4b). Further, each of the de-stacking lugs252is adapted to engage to at least one of the sets of de-stacking means240through an engagement means255(FIG. 4a). In a preferred embodiment of the present invention, the engaging means255includes an articulating engagement assembly270to movingly engage one of the sets of one or more de-stacking means240onto one or more de-stacking lugs252. In such an embodiment, each set of the one or more de-stacking means240is positioned onto a supporting plate242, having a first side242aconnected to a pair of de-stacking movers254a,254b, pivotally and movably attached to each other through one or more articulated mounting brackets272. The articulated bracket272is a conventionally known mounting bracket and includes a first attachment bracket274connected to a second attachment bracket276at their distal ends at a connection point C such that the articulated bracket has three open ends, i.e. a first open end274aat a proximal end of the first attachment bracket274, a second open end276aat the proximal end of the second attachment bracket276and a pivotally movable center end275at the connection point C.

Further, as illustrated inFIG. 4a, the articulated movement assembly270includes a first de-stacking mover254aconnected to a second de-stacking mover254bthrough the articulated mounting brackets272, each of the movers254a,254bconnected at one of the open ends274a,274bof the articulated bracket272, such that the articulated bracket272is pivotally movable in a generally perpendicular plane to the track throughout the longitudinal range of motion of the first mover254aand the second movers254b, towards and/or away from each other. The articulated assembly270is connected to the first side242aof the supporting plate242at the pivotally movable center end275thereof.

In a collapsed position, where the articulated mounting bracket272is closed, such that each of the pair of pivotally connected de-stacking movers254a,254bare oriented in a substantially coinciding position, the supporting plate242is at its initial position. In an opened position, where the articulated mounting bracket272opens up pivotally, the pair of the movers254a,254bmay be moved towards or away from each other such that the corresponding supporting plate242is moved perpendicular to the track which the movers traverse along, i.e. upward or pivotally towards or away from corresponding de-stacking lugs252a,252b.

One skilled in the art will recognize that the articulated movement assembly270having the pair of movers254a,254bis pivotally connected for longitudinal movement in a generally horizontal plane in a conventional manner. The articulated movement assembly270is movingly supported on to the closed loop conveying track230such that a horizontal longitudinal movement of the movers254a,254btowards and away from each other is possible. Such a movement of the pair of movers254a,254bprovides operative power for enabling the movement of the mounting bracket272between its collapsed position and its open position, thereby enabling a range of vertically upward and pivotal extensions along with a longitudinal movement of the shaping supporting plate242onto the closed loop conveying track230.

Therefore, by appropriate manipulation of the first mover254aand the second mover254band therefore the articulated assembly270, the supporting plate242and the corresponding set of de-stacking means240may be positioned at any desired distance away from the de-stacking lugs252, while moving in an operative orientation generally in a vertical and/or transversal and/or horizontal direction.

In yet other embodiments, the engagement means255may be any conventionally known mechanism suitable for supporting the set of one or more de-stacking means240onto the de-stacking lugs252and is selected from one or more of but not limited to a supporting plate as illustrated inFIG. 4b

In a modification of the first embodiment, as illustrated inFIG. 2, the denesting apparatus200includes multiple and preferably a pair of overhead closed loop conveying tracks230namely230a,230bfor denesting one or more stacks210including a first stack210apositioned onto a first stacking magazine220a, and a second stack210bpositioned onto a second stacking magazine220b.

In such an embodiment, the individual movement of the sets of de-stacking means240of each of the tracks230a,230bmay be utilized to speed up the process by utilizing either as a dedicated track230for predetermined stacks210or otherwise in situations where there is a need of simultaneously pick up and drop down of the sheets within stacks210onto the out-feed conveyor280. In yet other embodiments, de-stacking means240of both the tracks may be adapted to sequentially or simultaneously pick up the top sheet from the same stack210. In yet other embodiments, the sets of de-stacking means of the pair of tracks230a,230bmay be utilized in any possible manner so as to de-stack one or more, stacks210, onto the out-feed conveyor280.

This embodiment is particularly advantageous due to the fact that it provides multiple closed loop conveying tracks230and therefore the de-stacking means240each powered by a single light weight powering means for managing the operation of the denesting apparatus200and therefore is considered as a further efficient way to implement various embodiments of the present invention.

FIG. 2schematically show the arrangement of the basic components of the denesting apparatus200of the present invention. However, in the construction of commercial functional units, secondary components such as couplers, connectors, support structures and other functional components known to one of skill in the field of denesting apparatuses and more particularly the denesting of foldable blanks for use with conveyor systems, may be incorporated within the denesting apparatus200. Such commercial arrangements are included in the present invention as long as the structural components and arrangements disclosed herein are present. Accordingly, it is to be contemplated that the denesting apparatus200may be configured to be used for any kind of foldable blank of any possible shapes as deems possible without deviating from the scope of the current invention.

In a preferred embodiment, the one or more stacks of sheets210may be formed of a plurality of sheets in the form of foldable blanks, each adapted to form a primary or secondary package and/or a component thereof. For example, and as illustrated inFIG. 2, the first stack210apositioned onto the first stacking magazine220amay be stack of plurality of blanks each adapted to form a box shaped secondary package. Further, the second stack210bpositioned onto the second stacking magazine220bmay be a stack of plurality of partition sheets, each adapted to form a partition for the box shaped secondary package. However, in other embodiments, the stack of sheets210, may include any number of stacks of sheets, adapted to form any kind of output product, to be denested using the apparatus200of the present invention. Each of the stacking magazines220a,220bis connected to an incoming conveying line205each carrying a supply of stack of sheets220a,220brespectively.

In an embodiment and referring toFIGS. 3a-3d, the stacking magazines220are generally vertically movable storage racks222adapted to move between a top position PTand a bottom position PBthrough a vertical movement mechanism224. The top position PTis positioned at a height HTaway from a base platform corresponding to the base position PB, such that the top sheet of the stack210is positioned at a height HSsuitable to be picked up by at least one set of the de-stacking means240.

Further in such embodiments, in preferred instances, as illustrated inFIG. 3, the vertical movement mechanism224includes a vertical rail (not shown) positioned besides the storage rack222having one or more stacking movers226movingly configured thereon, and adapted to engage the storage rack222using a connecting member (not shown) such that the storage rack222is movable between its top position PTand the bottom position PBthrough the stacking movers226.

However, in other instances, the vertical movement mechanism224may be any suitable movement mechanism.

The denesting apparatus200further includes a retractable lifting means260, illustrated inFIGS. 3a-3dpositioned over each of the one or more stacking magazines220and adapted to support at least a sub-stack of the sheets, such that the top sheetis positioned at the height HSsuitable to be picked up at least by one set of the de-stacking means240of the one or more closed loop conveying tracks230.

In an embodiment, the retractable lifting means260is generally a flat lifting plate and is moveable vertically between a base position LBPand a top position LTPthereof, such that at any moment the top sheet is made to be positioned at the HSsuitable to be picked up by at least one set of the de-stacking means240. Further, the retractable means260is movable between an open position POand a retracted position PR(not shown). Such lifting plate may alternatively also consist of a plurality of forks that may move away or towards each other

In some instances, as illustrated inFIG. 3a, the base position LBPof the retractable lifting means260is generally same as the top position PTof the storage rack222of the stacking magazine220such that when moved to open position POfrom the retracted position PR, the retractable lifting means260supports the entire stack210thereon. Further, in such instances, the lifting means260moves vertically with removal of each top sheet to a distance same as a thickness of the sheet such that the top sheet is always positioned at the height HS. The top position LTPof the lifting means260is such that a bottommost sheet215(FIG. 3d) of the stack210is positioned as the top sheet. Once the stack210has been completely denested, lifting means260is adapted to retract back to the retracted position PRand vertically move down to the base position LBP.

The out-feed conveyor280is generally an outgoing conveyor positioned substantially below the one or more closed loop conveying track230at a height HCfrom the base platform, substantially similar to the height HTof the top sheet such that the already pick up top sheet may be suitably dragged and/or dropped onto the out-feed conveyor280for further processing.

The denesting apparatus200further includes a first powering means (not shown) for enabling a movement of the one or more closed loop conveying tracks230, the in-feed conveyor205, each of the one or more stacking magazines220, the retractable lifting mechanism260, the out-feed conveyor280and various sub-components thereof. In a preferred embodiment, the first powering means is a linear servo motor adapted to move each of the one or more closed loop conveying tracks230, the in-feed conveyor205, each of the one or more stacking magazines220, the retractable lifting mechanism260, the out-feed conveyor280at a first predetermined pitch facilitating a continuous operation of each of the components of the denesting apparatus200such that the incoming supply of the stacks of sheets210is continuously denested and transferred onto the out-feed conveyor280in any desired order and in any desired manner. However, in other embodiments, the first powering means is a linear servo motor adapted to move each of the one or more closed loop conveying tracks230, the in-feed conveyor205, each of the one or more stacking magazines220, the retractable lifting mechanism260, the out-feed conveyor280at a dynamically adjustable variable pitch facilitating an intermittent operation of each of the components of the denesting apparatus200such that the incoming supply of the stacks210of the sheets is denested and transferred onto the out-feed conveyor280, intermittently and when desired.

The denesting apparatus200further includes a second powering means (not shown) for enabling controlled independent movement of each of the movers including the de-stacking movers254, and optionally the stacking movers226along the corresponding tracks and/or rails. In a preferred embodiment, the first powering means is linear servo motor or equivalent thereof providing independent motion control of each mover. In such an embodiment, the linear motor is a generally moving magnet type of motor conventionally known in the art. Further in such embodiments, the linear motor utilizes the corresponding tracks and/or rails as a stator and each of the movers as a rotor thereof.

In other embodiments, the movers254,226are utilized as stator whereas the tracks or rails are utilized as the rotors. In such an embodiment, each of the movers254,226may include built in coils and each of the corresponding tracks or rails may include magnets configured thereon in a longitudinal direction such that the movers are able to come into an electromagnetic interaction, thereby enabling a movement thereof.

The denesting apparatus200may further include one or more control units (not shown) for managing the operations thereof, and particularly for managing the working of the first powering means and/or the second powering means and more particularly the movement of the de-stacking movers254aandb, so as to optimize the sequence of the longitudinal and/or vertical and/or transversal movement of the supporting plate242, and therefore the one or more support pads240, in a predetermined sequence. The predetermined sequence is particularly required to be evaluated in the instances where a specific predetermined order has to be followed for picking up the top sheets211, from the one or more stacks210.

In some embodiments, the control unit may include an input unit for receiving inputs related to the predetermined order of denesting the stacks210and the desired manner of discharge of the already picked up top sheets211, onto the out-feed conveyor280. Further, the control unit may include a plurality of sensors (not shown) for tracking the parameters such as for example, position, width and/or height of the of the sheets or blanks to be discharged, sheet or blank mis-alignment, for sensing when the one or more stacks210is empty, for sensing if the lifting means reached its top position, and the like. The control unit may further include a processor unit for processing the data captured by the input unit on the basis of predetermined logics/rules for facilitating the movement of the plurality of movers254,226, the vertical movement of the stacking magazine220, and the retractable lifting mechanism260. The control unit may further include an instruction unit that delivers the instructions to various components such as various powering means, linear motors, motors, driving units, or the like, to facilitate a desired and smooth operation.

In some embodiments, the control unit may be provided as a computer program product, such as may include a computer-readable storage medium or a non-transitory machine-readable medium maintaining instructions interpretable by a computer or other electronic device, such as to perform one or more processes.

In some embodiments, each of the plurality of sheets of the stack210is generally formed from a recyclable material selected from one or more of but not limited to any desired material such as including all kind of papers, fiberboard, corrugated board, foldable blanks, hybrid material, laminated board or any combinations thereof. Further, the shape and size, including the thickness of the sheets or blanks, and surface finish, may be varied depending on the design constraints and requirements for its application. In some other embodiments, the sheets or blanks may be made of a light weight plastic material selected from one or more of, but not limited to, plastic material such as group of thermoplastics including acetal, acrylic, cellulose acetate, polyethylene, polystyrene, vinyl, and nylon. In yet other embodiments, the sheets or blanks may be made of any material suitable to be denested using the denesting apparatus200, of the present invention

In an embodiment, the one or more de-stacking means240is formed of a conventionally known suction cup and/or vacuum cup having a generally bell-shaped structure and formed of a generally soft material such as a rubber, silicon, and the like, that is impenetrable by air. As may be contemplated by a person skilled in art, such de-stacking means240has been vastly utilized for lifting an object by application of vacuum created there within, when applied with a force against a flat surface such as a sheet. The number, size, and dimension of such de-stacking means240, is determined on the basis of weight, dimensions, and material of the sheets or blanks to be picked up from the stack210. In some embodiments, where the sheet or blank is of a heavy material, the denesting apparatus200may further be provided with a supply of negative pressure, for example, in the form of a vacuum creator, which may be utilized by de-stacking means240for picking such heavy sheets.

In a particular embodiment, variable suction force or vacuum at the point of application, at any location about the picking cycle may be applied for enabling faster cycle times. Further, control of the suction force or vacuum may avoid sheet material distortion and avoid the suction effect acting through porous materials and influencing optional other materials behind the porous primary material of the sheet.

In another embodiment, the air flow to the suction or vacuum cups may be reversed at discharging the sheet, thereby rapidly cancelling out the vacuum and applying a fast discharge force.

It is to be contemplated that while the number of stacks210has been mentioned as two in exemplary embodiments, the present invention may be utilized for any number of stacks without deviating from the scope of disclosure and depending upon the design constraints of the package to be formed. For example, in some instances, the one or more stacks210may include a first stack210aof foldable blank of carton, a second stack210bof a partition for the carton, a third stack210cholding sheet for forming a handle of the carton and so on. In other embodiments, the denesting apparatus200may be used to denest only a single stack210. In all such embodiments, the number of stacking magazines220remains equal to number of stacks210so as to individually support the stacks210thereon.

In a preferred embodiment of the present invention, each of the conveyors of the denesting apparatus200including the one or more closed loop conveying tracks230, the in-feed conveyor205, and the receiving conveyor280is generally a vertically positioned closed loop conveying track conventionally known in the art. In other embodiments, each of the conveyors of the denesting apparatus200including the one or more closed loop conveying tracks230, the in-feed conveyor205, and the out-feed conveyor280may be a generally horizontal positioned closed loop conveying track. In yet other embodiments of the present invention, each of the conveyors of the denesting apparatus200including the one or more closed loop conveying tracks230, the in-feed conveyor205, and the receiving conveyor280may be configured as a virtual closed loop conveyor.

The virtual closed loop conveyor, as known in the art, is generally a closed loop conveyor similar to a circular conveyor, in which the circular connecting edges of the conveyors on both the ends are replaced by straight shiftable conveyor portions adapted to move back and forth and avoiding the need of moving the movers through the entire circumference of the closed loop conveying track, and is therefore a very fast alternative to the conventionally known closed loop conveying tracks. Further, the closed loop conveyor being made of longitudinal rails, is therefore much more cost efficient than any conventionally known closed loop conveying tracks and/or conveyors. Additionally, the back and forth movement may also be helpful in providing additional pressure while performing operations such as pushing operation is therefore further preferred.

While the stacking magazine220has been disclosed to be a generally vertically movable supporting rack222, in some embodiments, the stacking magazine220may be inclined to the vertical or otherwise a horizontal conveyor (not shown) adapted to receive a supply of stacks210of the sheets or blanks such that the top sheet of one of the stack210is positioned at a distance suitable to be picked up by the one or more de-stacking means240. Further, once the stack210is nearly exhausted, another stack210is positioned at the distance suitable to be picked up by the one or more de-stacking means240such that there is no interruption there between.

In use, as disclosed earlier, the denesting apparatus200is adapted to be positioned onto an input line of a package manufacturing unit provided with one or more stacks210of foldable blanks for forming generally box shaped secondary packages. The denesting apparatus200denests the foldable blanks from the one or more stacks210placed onto the one or more stack magazines220in any predetermined order and places onto the out-feed conveyor280in any desired manner. Each of the stacks210is denested in a generally top to bottom manner, however, not restricted to any particular way of denesting and therefore it is contemplated that the denesting apparatus of the present invention may be utilize to perform denesting operation in any possible way without deviating from the scope of the present invention.

FIG. 5with reference toFIGS. 1 through 4, is a flow diagram illustrating a method600of de-stacking sheets or blanks from one or more stacks210thereof placed onto one or more stacking magazines220, either simultaneously, or otherwise sequentially in any desired manner, either one besides other or otherwise in an overlapping manner, using denesting apparatus200of the present invention.

The present invention relates to a denesting apparatus200for continuously and/or intermittently at a constant and/or variable speed, de-stacking sheets individually from one or more stacks in any desired order and discharging them onto an out-feed conveyor in any desired manner.

Additionally, the possibility of providing different kind of pushing sequence to the one or more sets of de-stacking means240allows picking up the top sheets211in any desired order and discharging in any desired manner. Such an optimized and focused picking up and dropping down the sheets in addition to a complete control of the speed, direction of the placement of the sheets, allows the possibility of using a same conveying line for discharging multiple sheets together while utilizing the width of the out-feed conveyor and avoiding misalignment and therefore, any damage to the sheets being discharged there through.

Particularly, the present invention is additional advantageous in providing an input line of packaging apparatus of different sub-parts of the packages, in accordance with the predetermined shape and configurations of the packages to be achieved.

Further, the denesting tool is adaptable to different dimensions of foldable blanks and is therefore well suitable to process packages of different sizes and shapes with ease and efficiently and not requiring changing the entire apparatus for denesting sheets of different predetermined shapes and sizes.

Further, the present invention provides the possibility of manufacturing the conveyor system with integrally formed denester apparatus200. Such a conveyor system for forming secondary package, while being cost-efficient, is very quick and easy to use and offers comfortable handling of packages of any shape, size or any variety of configurations.

Additionally, since the denester apparatus of the present invention while being applicable onto the conveyor system, does not impact the rest of the conveying process. A single conveyor system may utilize as many as denesting apparatuses within the same arrangement. Further, in case of one denesting apparatus is not working, rest can keep working and therefore, the fault tolerance of the plant can be increased.

While the denesting apparatus200of present invention has been disclosed with reference to foldable blanks, it may be used to denest all currently known sheet types, e.g., constructed of materials such as thermoplastic, hybrid materials, woven metallic fabric that may include ferrous or nonferrous metals, etc., or any other suitable material. Even in instances where heavy sheets are to be picked up, the strength or number of de-stacking means240may be adapted in accordance without having to change the entire apparatus200.

Moreover, it is also contemplated for a person skilled in the art that the denesting apparatus200of the present invention may be implemented in various industries such as food industry, transport industry, house hold appliance industry in denesting of any kind of product or group of products, of any shape, size or any variety of configurations, without limiting it to the packaging industry.