Method and apparatus for removing goods from a two-part carton

An apparatus for removing goods from a two-part carton having a base and a lid, the base being formed with side walls having external gussets secured against external side faces of the carton, the apparatus including: a lid removal module for engaging the lid and removing it from the carton; expansion members configured to be advanced between the gussets and the external side faces of the carton to remove the gussets from the side faces; engagement members for engaging side walls of the base and drawing them away from the goods and holding them in a position away from the goods; and a goods transfer module for engaging the goods and removing them from the carton.

CROSS-REFERENCE TO RELATED APPLICATION

This application is the National Phase, under 35 U.S.C. § 371(c), of International Application No. PCT/AU2020/050821, filed Aug. 7, 2020, which claims priority from Australian Application No. AU 2019902855, filed Aug. 9, 2019. The disclosures of all of the referenced applications are incorporated herein by reference in their entirety.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

FIELD OF THE INVENTION

The present invention relates to a method and apparatus for removing goods from a carton, such as a block of frozen meat or seafood for example.

BACKGROUND

For the transportation of perishable goods, it has been proposed to use cartons formed of a combination of barrier papers and board so that liners such as polyethylene bags can be avoided as they can become entrapped in the goods when frozen, potentially contaminating the goods.

Australian patent application no. 2016225886 discloses such a carton. It can be seen from this disclosure that the carton is folded in a unique way to prevent contact between the raw side edges of the carton and the goods. In particular, the carton is formed with external gussets that are secured to an external side of the carton.

Australian patent application no. 2017204053 discloses a machine for erecting such a carton. It can be seen that the nature of the carton presents challenges for using such a carton.

It is desirable to provide an automated machine for decartoning or removing goods from such a carton. Presently, removal of goods from such a carton is performed manually, which is labour intensive, susceptible to process error and can lead to injury.

One particular issue with removing goods from such a carton arises due to the goods being stuck to carton and somewhat difficult to remove. Another issue is that the goods may be partially defrosted, which can lead to a soggy carton that tears easily and which can lead to contamination of the goods.

There is a need to address the above, and/or at least provide a useful alternative.

SUMMARY

According to one aspect of the invention, there is provided an apparatus for removing goods from a two-part carton having a base and a lid, the base being formed with side walls having external gussets secured against external side faces of the carton, the apparatus including:

a lid removal module for engaging the lid and removing it from the carton;

expansion members configured to be advanced between the gussets and the external side faces of the carton to remove the gussets from the side faces;

engagement members for engaging side walls of the base and drawing them away from the goods and holding them in a position away from the goods; and

a goods transfer module for engaging the goods and removing them from the carton.

According to another aspect of the present invention there is provided an apparatus for removing goods from a two-part carton having a base and a lid, the lid being formed with flaps extending downwardly therefrom and the base being formed with side walls having externally folded down upper portions and external gussets secured against external side faces of the carton, wherein the flaps of the lid are secured to the folded down upper portions of the base, the apparatus including:

slitters for cutting along sides of the carton to cut through the flaps of the lid and partially into the folded down upper portions of the base;

a lid removal module for engaging the lid and removing it from the carton;

expansion members configured to be advanced between the gussets and the external side faces of the carton to remove the gussets from the side faces;

engagement members for engaging side walls of the base and drawing them away from the goods and holding them in a position away from the goods; and

a goods transfer module for engaging the goods and removing them from the carton.

According to preferred embodiments of the invention, the expansion members are wedges. Preferably, the expansion members are driven upwardly from below the carton.

The engagement members can include suction cups configured to engage a first pair of side walls of the carton, the first pair of side walls are generally parallel with a path of travel of the carton. The engagement members can include rods that extend downwardly to engage a second pair of side walls of the carton to draw them away from the goods, the rods pinning the second pair of side walls against a transfer conveyor to hold them in position.

Preferably, the goods transfer module includes fingers configured to pierce the goods for engagement thereof. Preferably, the goods transfer module is configured to tilt the goods and release them from the carton.

The slitters may be fixed in position and include spring loaded blades that follow the contour of the carton. The apparatus can further include at least one conveyor belt for transporting the carton through the apparatus, the conveyor belt/belts moving the goods between an initial position, a lid removal station, and a goods removal station.

Preferably, the slitters contact the first pair of side walls of the carton during movement from the initial position to the lid removal station. The slitters may contact the second pair of side walls of the carton when positioned at the lid removal station. Preferably, the slitters for contacting the second pair of side walls of the carton are fixed to the lid removal module.

In preferred embodiments, the carton moves in a generally straight path and the lid removal module moves perpendicular to the path of movement of the carton. Once the goods are removed from the carton, the empty carton is preferably transported along a further conveyor disposed perpendicular to the at least one conveyor belt. Preferably, the lid removal module engages the lid with suction cups.

Preferred embodiments further include an imaging system configured for scanning an internal surface of the base and/or lid of the carton once the goods are removed, the imaging system configured to identify missing carton fragments that may be attached to the goods.

According to another aspect of the invention there is provided a method of removing goods from a two-part carton having a base and a lid, the lid being formed with flaps extending downwardly therefrom and the base being formed with side walls having folded down upper portions and external gussets secured against external side faces of the carton, including the steps of:slitting sides of the carton to cut through the flaps of the lid and partially into the folded down upper portions of the base;removing the lid;driving expansion members between the gussets and the side faces to remove the gussets from the side faces;drawing side walls of the carton away from the goods; andengaging the goods and lifting them from the carton.

In preferred embodiments, the goods are tilted to release them from the carton.

Preferably, the expansion members are wedges driven upwardly from underneath the carton.

The method can further include the step of using an imaging system to scan an inside surface of the carton after the goods have been removed to check for missing fragments.

DETAILED DESCRIPTION

An apparatus10according to a preferred embodiment of the invention is shown inFIG.1. The apparatus10is configured for removing goods from a two-part carton20such as that shown inFIG.2, or carton20aofFIG.3.

As illustrated inFIGS.2and3, cartons20,20ahave a base22and a lid24. The lid24is formed with flaps26extending downwardly therefrom and the base22is formed with side walls28having externally folded down upper portions30and external gussets32secured against external side faces of the carton20. In use, the flaps26of the lid24are secured to the folded down upper portions30of the base22.

Carton20may be configured as per that described in Australian provisional patent application no. 2015903825, and its corresponding related applications, the entire contents of which are incorporated herein by reference. Although the carton is shown as being rectangular, those skilled in the art will appreciate that the carton may take other shapes, such as a square for example, and have other proportions. Furthermore, lid24may take other forms, having side walls26that extend over substantially the entire side of the carton20. Preferably, the corners of the lid24are trimmed as shown, to facilitate removal, though it will also be appreciated that such trimming may be omitted.

Also, inFIG.2gussets32are shown as being folded down over the long side walls, forming a leak proof flap along that side, though the gussets may also be folded down over the short side walls, as shown in relation toFIG.3. It will be appreciated that the form of side flaps30will vary according to whether the gussets fold down on the short side or long side of the carton.

Apparatus10includes slitters12a(FIGS.4,6,7,10and13) and12b(FIGS.1,4,6,7,10,12and13) for cutting along sides of the carton to cut through the flaps26of the lid24and partially into the folded down upper portions30of the base22, a lid removal module14for engaging the lid24and removing it from the carton20, expansion members16(FIGS.5,6,7,12,13and15) configured to be received between the gussets32and the external side faces of the side walls28of the carton20to remove or detach the gussets from the side faces, engagement members18(FIGS.5,6,7,12,13and15) for engaging the side walls28of the base22and drawing them away from the goods and holding them in a position away from the goods, and a goods transfer module19(FIGS.1,4,7,8,9and14) for engaging the goods and removing them from the carton.

In alternative embodiments, lid24is not glued to base22but secured with other means, such as straps extending around the outer surface of the carton20for example. In such embodiments, the straps may be cut manually before the carton is loaded into the apparatus10, or may alternatively be removed by an automated de-strapping device located at entry point A.

In the described embodiments, the contents of the carton are goods in the form of a solid block. The goods may be in a singular piece or multiple individual pieces. In preferred embodiments, the goods are a frozen block of foodstuffs, and preferably meat or seafood products, though those skilled in the art will appreciate that the goods may also be dairy products such as cheese, or produce such as fruit or vegetable products, that may or may not be frozen, for example.

Apparatus10includes a conveyor belt34(FIGS.4,7,8,9,10,11,12,13and15) to move carton20along a generally straight path indicated as X inFIGS.1,4and7. It will be appreciated that the conveyor belt34may be a single belt or made up of multiple sections of conveyor belt.

In the described embodiments, carton20move along its longitudinal axis or long ways, though it will be appreciated that the carton20may also move along a transverse axis or sideways.

As can be seen inFIG.7, the carton20starts at an initial position A and moves from there to a lid removal station B, and then to a goods removal station C, each of which will be described in further detail below. In the illustrated embodiments, separate sections of conveyor34, each driven by their own respective motor35, are used to move the carton20from the initial position A to the lid removal station B, to the goods removal station C.

Initial Position A

Carton20is loaded into apparatus10at position A (FIG.7). This may be completed manually from a pallet of stacked cartons20or loaded by machine. Carton20may wait in the initial position until lid removal station B is free and the carton can be advanced forwardly to the lid removal station B (seeFIG.7).

Lid Removal Station B

In moving carton20toward station B, the carton20comes into contact with slitters12awhich slit along a long side of the carton20. The position of slitters12acan be seen inFIG.7. Slitters12aare fixed in position and include spring loaded blades that follow the contour of the carton20, thereby accommodating any misalignment of the carton20on the conveyor34, or bulging of side walls of the carton20due to the weight of the goods or freezing. In alternative embodiments, slitters12a,12btake other forms such as rotary knives for example.

When the carton moves to station B, it may come into contact with stops or guides to ensure consistent positioning upon arrival.

When carton20is at the lid removal station B, lid removal module14advances toward the carton20to remove the lid24. The lid removal module14moves along path Y, as shown inFIG.7, which is perpendicular to the path of movement X of the carton.

As can be seen inFIGS.12and13, the lid removal module14has slitters12bfitted thereto, which move across the short sides of carton20as it sits at the lid removal station B, to complete slitting of the lid24to allow removal from the carton20.

Each of slitters12a,12bcut through the flaps26of the lid24and partially into the folded down upper portions30of the base22. The slits are made to an upper portion of the flaps26so as to be above a glue line which fixes the lid24to the base22, thereby allowing the lid24to be removed from base22after cutting.

The lid removal module14engages the lid24to remove it from the carton20. Once engaged, the lid removal module14lifts the lid24from the carton20and retracts away from the carton20along path Y so that the lid24can be dropped into a bin36(FIGS.4,5and10) for disposal. Bin36is preferably provided with wheels so that it can be interchanged with another like bin when full. A distance sensor within bin36may be provided to detect when the bin is full or approaching full. Alternatively, for high volume environments a conveyor or autonomous vehicle may be provided for transporting removed lids22from the apparatus10.

In the lid removal module14shown inFIGS.12and13, suction cups38are used to engage the lid, though it will be appreciated that other forms of engagement, such as grippers or spikes may also be used.

In the illustrated embodiments, four suction cups38are used, each one being positioned near a corner of the lid24, though it will be appreciated that less than or more than four suctions cups may also be used.

The lid removal module14runs on tracks and belts driven by electric motor40, though it will be appreciated that other mechanisms and types of drives may be used.

Goods Removal Station C

Once lid24has been removed from carton20, and goods removal station C (FIG.7) is free, the carton20is moved from station B to station C, where the goods are removed from the carton20.

Once in position, expansion members16are driven upwardly from below carton20by pneumatic cylinders17and received between the gussets32and the external side faces of the side walls28of the carton20to remove the gussets32from the side faces. It will be appreciated that in alternative embodiments, the expansion members16may also be driven downwardly from above the carton20.

To ensure that the carton20is positioned so that the expansion members16can accurately be driven between the gussets32and the side walls28, a guide or stop may be provided to position the carton20as required. Alternatively, clamps may also be used to move and hold the carton20in position.

In the illustrated embodiments, the expansion members16are in the form of solid wedges, though they make take other forms. For example, the expansion members16may be plates hinged together at one end and separable at the other end to form wedges in an expanded state. In other forms, the expansion members may be hooks that hook under the gussets32and allow the gussets32to be drawn away from the external side faces of the side walls28.

By providing wedges in the preferred embodiments, the gussets32can be gently detached from the external side faces of the side walls28, without damaging the gussets32or the carton20. Detaching the gussets32can be difficult, particularly if the carton20is damp or soggy, in which case it may tear easily.

Once the gussets32have been detached from the carton20, as shown inFIGS.9and11, engagement members18(FIGS.5,6,7,12,13and15) are used to engage the long side walls28of the base22and draw them away from the goods. Engagement members18are driven upwardly by pneumatic cylinders17.

In one embodiment, the engagement members18includes suction cups44configured to engage the side walls28of the carton20. Suction cups44are mounted in plates46. In the illustrated embodiments, the plates46are hinged and swing downwardly to draw the side walls28away from the goods and hold them in a generally horizontal position while the goods are removed from the carton. Multiple, spaced apart suction cups are used to ensure sufficient engagement with the side walls28.

Once the long side walls28are drawn away from the goods and held down, the short side walls are then required to be drawn away from the goods and held down. Suction cups may be used for this function also, though in the illustrated embodiment, rods48are used and advanced downwardly from above the carton20to engage the side walls28, draw them downwardly and away from the goods, and pin them to the conveyor belt34while the goods are removed from the carton20.

Rods48may move sequentially or together and may be driven by linear actuators or pneumatically.

To assist with removal of the goods from the carton20, once the gussets32are detached or released from the side of the carton20, they may be engaged and pulled outwardly to disengage an inner surface of the side walls28from the goods.

Once the side walls28have been drawn away from the goods and held in position, the goods can be removed from the carton20. To this end, the goods transfer module19engages the goods and lifts them from the carton20and transports the goods to an exit conveyor50.

In the illustrated embodiments, the goods transfer module19includes fingers or spikes configured to pierce the goods for engagement thereof. Fingers or spikes are used as the goods may be a frozen block of meat, which is typically irregular in shape and can be difficult to grip. Preferably, the fingers or spikes are formed of stainless steel. It will be appreciated that in other embodiments, the goods transfer module19may include grippers or other means for lifting the goods from the carton20.

The module19travels on a carriage52driven by motor53, and is configured to lift the goods before moving them to the exit conveyor50, which is a food contact surface. In preferred embodiments, the module19is provided with some float and configured to slightly twist or tilt the goods during lifting to release them from the carton, starting at one corner. This may break adhesion and minimise adhesion resistance forces and can assist in the goods coming away from the carton20in a single continuous block without breaking up.

Once the goods are removed from the carton20, the empty carton is transported by a transfer module54in a direction perpendicular to direction X, towards a bin56for disposal. The transfer module54may engage the empty carton via a suction cup55.

Alternatively, the empty carton20may be dragged across to bin56(FIG.5).

By holding the carton in place and moving the goods away from the carton, any contamination on the external surface of the carton can be kept away from the goods.

An imaging system or optical scanning system including a camera or optical scanner58may be provided for scanning an internal surface of the base22of the carton20once the goods are removed. The extent of the area scanned by the camera/optical scanner is shown in the drawings as item59.

The imaging system may include a conventional camera for taking a digital photograph or an infra-red camera. Alternative imaging systems such as X-ray systems may also be used.

A second camera/optical scanner may be provided at station B for scanning the lid24of the carton20once removed. The lid24is preferably scanned from underneath.

The imaging/optical scanning system is configured to verify that the carton is intact and that there are no carton fragments are missing, which could be attached to the goods. However, verification that the goods are free from carton contamination can only be done by checking the goods. To obtain such verification, the imaging/optical scanning system may be configured to scan the goods directly. It will be appreciated that the imaging/optical scanning system may scan only the carton or the goods, or scan both the carton and the goods. In the event that any fragments are detected as missing from the carton, the apparatus10may be configured to stop or to automatically quarantine the potentially affected goods for further inspection.

In use, the captured images may be processed electronically by a processor, or manually via an operator. If an operator is used, a number of photos may be queued or displayed together on a display screen to be reviewed at the same time. Preferably, the goods are indexed or sequenced for easy matching in the event that the scanning system identifies goods or carton bases22or lids24that require further inspection. In some embodiments, a food grade dye may be applied to the goods and/or bases22/lids24to flag that further inspection is necessary.

Although not shown, it will be appreciated that the apparatus10can include other components for safe and reliable function, such as safety guards and cut-off switches and controls, all of which may be controlled via a main control cabinet60.

Apparatus10is configured for use in a food processing environment and to meet relevant food processing standards, meeting wash down requirements etc.

The embodiments have been described by way of example only and modifications are possible within the scope of the invention disclosed. For example, the described pneumatic actuators may be substituted with electrical actuators or mechanical linkages. Instead of conveyors, the carton20may be pushed along a roller surface and engagement of the goods for removal of the carton may be performed in other ways.

Preferred embodiments of the invention can provide an automated apparatus for removing goods from a two-part carton, potentially reducing cycle times over manual operations and saving labour costs. When used to remove frozen goods, the number of people operating in a low temperature environment can be reduced. Also, additional steps previously taken to reduce adhesion between the goods and the carton, such as increasing the temperature of the goods either when stored or by microwaving, can be avoided.

REFERENCE NUMERALS

10Apparatus for removing goods from a two-part carton12a,12bSlitters14Lid removal module16Expansion members17Pneumatic cylinders18Engagement members19Goods transfer module20Two part carton22Base of carton24Lid of carton26Flaps of lid28Side walls of base of carton30Externally folded down upper portions of side walls32Gussets of base of carton34Conveyor belt35Conveyor belt motor36Bin for disposal of carton lids38Suction cups40Motor42Side wall engagement members44Suction cups of engagement members1846Plates48Rods50Exit conveyor52Carriage53Motor54Transfer module55Suction cup56Bin58Camera/Optical scanner59Extent of optical scanner60Main control cabinet