Patent Publication Number: US-2019179292-A1

Title: System and method for carton serialization

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority of Provisional Ser. No. 62/595,743, filed Dec. 7, 2017, the disclosure of which is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to high-speed production, gluing and folding of feed stock to form cartons and, more particularly, to carton serialization. 
     BACKGROUND OF THE INVENTION 
     In carton assembly systems, the feed stock to form the carton moves on a conveyor past a glue station where glue is applied to a portion thereof. After the glue is applied to the carton, the carton is folded and pressure is applied to the carton while the glue dries. Sometime later, the cartons are filled with a product. If the cartons are improperly glued, the cartons may come apart, for example, during shipping, and the product may be damaged or lost. Therefore, it is desirable to detect improper assembly of the carton. 
     Particularly, typical packaging automation systems include high-speed lines which take feed stock in the form of precut and printed paperboard, or the like, and form a packaging product, such as a carton, box, bag, envelope, or the like. For simplicity herein, the packaging product will be referred to as a carton formed of paperboard. As will be apparent, the invention is not intended to be so limited. 
     Of relevance herein are systems which take the flat paperboard stock and at high speed add glue and fold the paperboard into a carton for use by the end customer. Such systems include apparatus for analyzing for improper placement of glue, folds, or the like and immediately rejecting the carton if an error is found without slowing down production. 
     However, if a carton is produced and shipped to the customer and there is subsequently an issue, then it would be useful to know how the carton was produced. Being able to track each carton produced and determine how it was produced provides advantages to satisfy a customer&#39;s needs and avoid future problem. 
     The present invention is directed to improving availability of and access to information on individual cartons. 
     SUMMARY OF THE INVENTION 
     In accordance with the invention, high-speed production lines for carton assembly are adapted to include carton serialization to allow for analysis of each individual carton produced. 
     There is disclosed in accordance with one aspect a system for carton serialization on a high-speed production line for selectively gluing and folding feed stock to form an assembled carton. The system includes conveying apparatus for delivering feed stock from a feed unit to a delivery unit. A sensor senses feed stock entering the conveying apparatus. A printer prints a unique character string on each piece of feed stock to uniquely identify each assembled carton. Folding and gluing apparatus are operatively associated with the conveying apparatus for selectively gluing and folding feed stock to form assembled cartons. An analysis apparatus monitors operation of carton assembly. A rejection device selectively removes defective assembled cartons from the conveying apparatus. A control system is in operative communication with the sensor, printer, folding and gluing apparatus, the analysis apparatus and the rejection device. The control system stores machine operating parameters in a database. The control system controls the printer to print the unique character string on each piece of feed stock responsive to the sensor and storing the unique character string and production time for each carton produced in the database. The control system selectively provides serialization reports providing machine operating parameters for each assembled carton. 
     It is a feature that the control system triggers timing of the printer based on a signal from the sensor and speed of the conveying apparatus. 
     It is another feature that the control system transfers a selected character string to the printer at the beginning of each print operation, and the printer selectively increments the character string printed on each carton responsive to receiving a print command from the control system. 
     It is another feature that the printer sends a print acknowledgement signal to the control system after printing the unique character string on each carton. The control system may wait for the print acknowledgement signal after triggering the printer to ensure that the system maintains synchronization. The control system is adapted to selectively stop the conveying apparatus, stop a feeding apparatus or take no action if the system does not maintain synchronization. 
     It is a further feature to provide a remote processing system in operative communication with the control system for remotely accessing real-time data, statistics and reports for any carton produced by using the unique character string. 
     It is yet another feature that for each carton removed by the rejection device, the control system stores a specific reason for rejection associated with the unique character string for the carton. 
     It is an additional feature to provide a remote database and the control system periodically uploads production data and serialization of reports from the database to the remote database. 
     It is still a further feature that an image analysis device operatively associated with the control system reads the unique character string to ensure proper printing of the unique character string. 
     There is disclosed in accordance with another aspect a method for carton serialization on a high-speed production line for selectively gluing and folding feed stock to form an assembled carton comprising: providing a conveying apparatus for delivering carton feed stock from a feed unit to a delivery unit; sensing feed stock entering the conveying apparatus; printing a unique character string on each piece of carton feed stock to uniquely identify each resulting assembled carton; automatically gluing and folding carton feed stock fed on the conveying apparatus to form assembled cartons; monitoring operation of carton assembly; selectively removing defective assembled cartons from the conveying apparatus; and operating a control system to store machine operating parameters in a database, the control system controlling the printing of the unique character string on each piece of carton feed stock responsive sensing feed stock entering the conveying apparatus and storing the unique character string and production time for each carton produced in the database, and the control system selectively providing serialization reports providing machine operating parameters for each assembled carton. 
     Further features and advantages will be readily apparent from the specification and from the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a generalized block diagram illustrating an exemplary production system and method for carton assembly; 
         FIG. 2  is a more detailed block diagram of a control system for the production system of  FIG. 1 ; 
         FIG. 3  is a diagrammatic representation illustrating timing and distance for operation on the production line; 
         FIG. 4  is a flow diagram illustrating operation of software implemented in the control system of  FIGS. 1 and 2 ; 
         FIG. 5  is a state diagram illustrating printer control in the control system of  FIGS. 1 and 2 ; 
         FIG. 6  is a plan view of exemplary unfolded feed stock; and 
         FIG. 7  is a plan view of a carton formed from the feed stock of  FIG. 6 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As described herein, a carton assembly system and method are provided with apparatus and methodology for implementing carton serialization which prints a unique carton ID on each carton produced. The system sends job setting and carton ID information to a database which allows a user to query a specific carton ID and obtain the job settings used and time when the carton was produced. Also, the user can query information for a failed carton, such as the specific failure reason and chronological data related to that carton. 
     Complete process information about each carton, including precise gluing and quality assurance settings, is available. Such reports allow carton producers to understand the root cause of issues and offer immediate corrective action to avoid future problems. Serialization reports provide answers about each individual carton including, for example, when the carton was produced, what machine the carton was produced on, which detection settings were activate, issues with the preceding or subsequent cartons, the job settings, and the last machine stop prior to production of the carton at issue. Analysis can be used to reject cartons if a problem is found. 
       FIG. 6  illustrates a sample of flat feed stock S cut into a desired shape. The stock S has plural fold lines L. A glue area G represents an area where glue will be applied to adhere to a flap F after folding. The resultant carton C is shown in  FIG. 7 . 
     Referring to  FIG. 1 , a generalized block diagram illustrates an exemplary system for carton assembly. The system comprises a high-speed line  10 . The line  10  comprises a conveying apparatus that may produce up to 200,000 cartons per hour. The throughput of the line will depend, in part, on the carton size. Larger cartons allow the print to be “stretched” more and therefore could be run at higher speed than with smaller cartons. The line  10  includes a feed unit  12  which feeds stock from a bin  14 . The stock would typically be a flat, precut paperboard item, see  FIG. 6 , printed according to the user requirements. The stock is fed to a print section  16  which prints a unique product ID code on the carton. An analysis section  18  is optionally used to verify the product ID code. 
     Thereafter, the line  10  includes a folding and gluing section  20  which applies glue, as necessary, to appropriate places on the carton and subsequently folds the carton into its assembled state. A rejection section  22  is employed to reject a carton when an error has been found in the folding and gluing section  20 . If not rejected, then the cartons proceed via a transfer section  24  to a delivery section  26  and subsequently to a packing section  28  for delivery to the customer. 
     The configuration of the line  10  herein is intended to be by way of example only. The particular configuration of the line  10  is entirely dependent on the requirements for carton assembly. For example, there may be multiple gluing stations and fold stations, as necessary or desired. An example of such a system is illustrated in Leary et al U.S. Pat. No. 5,375,722, owned by the assignee of the present application, the specification of which is incorporated by reference herein. 
     This application is particularly directed to the use of carton serialization on such a line  10  to improve monitoring capabilities and analysis of individual cartons produced. 
     The line  10  is controlled by a local control system  30 . The control system  30  includes a programmed controller  32  which comprises a computer base controller including appropriate memory, such as a local database  33 , storing control programs and data. The controller  32  is connected to a user interface device  34 , such as a touch screen monitor. The controller  32  may be connected via a network  36  to the Internet  38 , see  FIG. 2 . A remotely located database, identified as data infrastructure  42 , also stores production data, as described. A remote Internet enabled device  40  may be connected to the remote database  42  for remotely accessing real-time data, statistics, and reports for carton producers. 
     The control system  30  uses known dynamic operating software for electronic gluing and quality assurance. The control system  30  is capable of ‘learning’ its glue pattern, is pre-programmed with a plurality of standard folded box designs and detects and automatically adjusts glue applications on the run. Conventional data collection software allows the controller  32  to send real-time statistical data to the remote database  42 . All data contained in the systems&#39; production reports are sent through the network, creating archived data and allowing tracking capabilities for basic or sophisticated production analysis. The software also allows download of data to industry standard (PDF, CSV, XLS) files, and integration via programmatic API access directly to the remote database  42 . 
     Standard production reports such as job tracking, production totals, total waste, down codes and defects are provided through the data collection software. Custom reports may also be generated based on specific plant criteria. Each of the reports can be customized by the user, making the program easy to run and eliminating the need for any in-house programming expertise. 
     The controller  32  includes plural I/O channels  44  for interfacing with peripheral devices. The peripheral devices may include a sensor  46  for detecting presence of feed stock on the conveying apparatus. A printer  48  includes a print head for printing the unique ID code. Optional image analysis device  50  can read the printed unique ID code as well as any other necessary information. Other known devices  52 , see  FIG. 2 , are used for applying glue, detecting glue, detecting other aspects of the carton production, and the like. A rejection device  54  is operable to displace a carton from the line in the rejection section  22 , if an error has been detected by the devices  52 , or the image analysis  50 . 
       FIG. 3  illustrates the timing relationship between various elements for controlling the printer  48  for printing the unique ID. The line  10  also includes an encoder  56  which senses line speed proximate the printer  48 . The figure shows a sample carton C which is conveyed on the line  10  from right to left from the feed bin  14  of the feed unit  12 . The sensor  46 , such as a photo eye, is a select distance ahead of the print head of the printer  48 . The system must also know a carton lead distance which is a user defined space between the leading edge of the carton C to the position on the carton C where the unique ID is to be printed. Based on the carton lead distance and the distance from the printer  48  to the photo eye  46 , and knowing the speed sensed by the encoder  56 , the controller  32  can determine how long after receiving the trigger signal to initiate operation of the printer  48 . Moreover, the system must take into account any print stroke delay, as indicated at a block  58  and print response time as indicated at a block  60  to determine when the print command should be sent to the printer  48 . The controller  32  must also know the distance to the rejection device  54  as any errors must be sensed during the time that the carton transitions to the rejection device  54  if an error is detected. 
     Referring to  FIG. 4 , a flow diagram illustrates the methodology used with the control system  30  for controlling operation of the line  10 . Particularly, the system is adapted for implementing a method for carton serialization. 
     The control system  30  begins during startup for a “job” at a block  100  which creates and loads information for the job. The job would relate to the production of a particular carton for a customer and defines parameters for folding and gluing and the like, in a conventional manner. An operator then logs in at a block  102  and creates or loads the unique ID codes at a block  104 . The parameters for such codes are discussed in greater detail below. The control system  30  then learns the carton process at a block  106  which determines how the folding and gluing sections  20  will be controlled to assemble the carton. 
     Machine operation is then described for a “running” operation beginning at a block  108  where the feed stock for a carton C is fed from the feed unit  12 . Once the feed sensor  46  senses a carton C, at a block  110 , then the controller  32  sends a command at a block  112  to print the unique ID on the individual carton C. The unique ID is printed using the printer  48 . The printer  48  is triggered based on the signal from the sensor  46  and knowing line speed, as discussed above. An example of a carton C is shown adjacent the block  112  showing a unique code “123-ABC” printed thereon. As is apparent, the control system  32  could print a non-alpha numeric code, such as a string encoded in other code symbologies, or as a data matrix. 
     The image analysis device  50  reads the printed ID code at a block  114 . The image analysis device  50  may be anywhere downstream of the printer  48 . A block  116  control various aspects of the folding and gluing section  20  to glue and fold the carton, as necessary for the particular job, and uses the available monitoring apparatus to determine if the particular carton is acceptable. The carton may be rejected at a block  118 , based on the ID being improperly printed, as determined at the block  114 , or based on control of the quality assurance software at the block  116 . The carton data and machine data corresponding to the time at which the individual carton C is produced is stored in the local database  33  at a block  120 . 
     The operation relative to the blocks  108 - 120  is continually implemented as long as the line continues to run which, as noted above, may be at speeds up to 200,000 cartons per hour. While the individual blocks are listed sequentially, various operations are performed simultaneously as multiple cartons are present on the line at any given time. The sequence is described for a single carton and is repeated for each and every carton being assembled, as is apparent. 
     Periodically during the run, or at the conclusion of the run, the carton data is uploaded from the local database  33  to the remote database  42  at a block  122  and stored at a block  124 . The data is then available for delivery to a portal accessed via the device  40 , see  FIG. 2 , at a block  126  so that a user can look up carton data at a block  128  and to determine system operation at the time that any particular carton or cartons were produced, as described more particularly below. Reports can also be prepared at a block  130  for viewing and/or printing. 
     In an exemplary embodiment, the controller  32  prints a unique string on each carton, see  FIG. 6 . The unique string may include indicia representing the machine line number, the start time of the current job and the unique carton number. As will be appreciated, other unique strings may also be used, such as customer supplied codes. The controller  32  sends a digital I/O print signal to the printer  48  for each carton. The printer  48  may be, for example, a Domino continuous ink jet printer. The printer  48  will print the string that was given when it receives a signal. The printer  48  sends a successful acknowledgment to the controller  32 . The printer  48  will also increment the string by one so that the next carton will have a unique string printed. 
     The exact time of when the printer  48  is triggered is based on several factors, such as the signal from the sensor  46 , line/machine speed, the print delay  58  specified in the printer configuration, the printer dot pitch, the time it takes for the ink to drop from the print head (print response time  60 ), the distance from sensor  46  to the printer  48 , and the desired location for the print to begin on the carton. 
     The printer  48  is managed by the controller  32  using a software finite state machine (FSM). The software transitions from one state to another when an event occurs. 
       FIG. 5  illustrates the various states and events for transitioning from one state to another. Each state in the machine is shown as a block in  FIG. 5 . Each line in the diagram is an event. 
     The FSM is initialized to an idleStopped state  140  which means that the line  10  is stopped. If the control system  30  has just started, then the FSM transitions to the cartonTextSend state  142  to instruct the printer  48  what to print. Also, when the job has changed, the FSM transitions to the cartonTextSend state  142  to instruct the printer what to print. Likewise, if the operator ID has changed, the FSM transitions to the cartonTextSend state  142  to instruct the printer what to print. If a printing error occurred while printing, the FSM transitions to the cartonTextSend  142  state to instruct the printer what to print. When an idle timer expires or at a first machine stop, the FSM transitions to a statusSend state  144  to check the printer status. If the machine starts, the FSM transitions to an idleRunning state  146 . 
     If the FSM is in the idleRunning state  146  the machine is running as at the blocks  108 - 120  of  FIG. 4 . When each carton reaches the proper position under the print head, as discussed above, and the FSM transitions to a cartonPrint state  148  to trigger the printer  48  to print. If the machine stops, the FSM transitions to the idleStopped state  140 . 
     If the FSM is in the cartonPrint state  148  the printer  48  is signaled to print. The printer  48  is activated and the FSM transitions to a printAck state  150  to wait for an acknowledgement (ACK). 
     If the FSM is in the printAck state  150  it is waiting for an ACK from the printer  48 . If an ACK from the printer  48  is received, the FSM transitions to the idleRunning state  146 . If the ACK wait timer expires, the FSM takes the action it is configured for on printer errors and transitions to the idleRunning state  146 . 
     If the FSM is in the cartonTextSend state  142  it will send the text to print to the printer  48 . The controller  32  sends the current text to be printed to the printer  48  and transitions to a cartonTextAck state  152  to wait for an acknowledgement while the message is queued. 
     If the FSM is in the cartonTextAck state  152  it is waiting for an ACK from the printer  48 . When an acknowledgement that the printer is ready is received from the printer  48 , the FSM transitions to the idleStopped state  140 . If the wait timer expires, the FSM assumes the printer  48  is offline and transitions to the printerOffline state  154 . 
     If the FSM is in the statusSend state  144  it is sending a status request to the printer  48 . The FSM sends a status request message to the printer and transitions to a statusWait state  156  to wait for an acknowledgement. 
     If the FSM is in the statusWait state  156  it is waiting for status response. If a status response is received the FSM transitions to the idleStopped state  140 . If the wait timer expires, the FSM assumes the printer is offline and transitions to the printerOffline state  154 . 
     If the FSM is in the printerOffline state  154  the printer is not responding. When the wait timer expires the FSM transitions to the statusSend state  144  to check if the printer  48  is back online. 
     The print string transferred from the controller  32  to the printer  48  typically consists of at least one of several identifying pieces of information, such as the machine number, the start time of the job, and the carton ID within that job. Users may also choose to print other identifying information, such as an ID of the operator running the machine, a timestamp, or other custom-supplied information. 
     An operator may login at any time or be automatically asked to login at a shift change. This process is made easier by use of a fingerprint scanner. Once the operator registers a fingerprint, he or she can then quickly login to the system at the block  102 . This may affect the printed code if the option is chosen to print the operator&#39;s name or initials on the carton. 
     The commands used to set the print string on the printer  48  may require up to 500 ms for the printer  48  to process. At typical machine speeds, several cartons would pass by the print head in that amount of time. Therefore, the print string cannot be given to the printer  48  for each carton printed if the machine is to be run at high speeds. 
     To mitigate this issue, the print string is sent to the printer  48  each time the job changes and whenever the machine is stopped. Furthermore, the job cannot be changed while the machine is running. Also, the printer  48  is configured to increment the carton ID portion of the string each time it is triggered to print. Each time the printer  48  is triggered to print, the printer  48  provides an acknowledgement that the operation was performed successfully, as described above. After triggering the printer  48 , the controller software waits for the acknowledgement and treats the carton as a reject if the acknowledgement does not arrive in the expected timeframe. Any carton that is not printed on is treated as a reject. 
     The interactions between the controller  32  and the printer  48  can be complex, and several synchronization challenges can arise. There are some specific methodologies employed to overcome these challenges. 
     One option is to stop the entire line  10 . After triggering the printer  48 , the controller software waits for the acknowledgement and stops the line  10  if the acknowledgement does not arrive in the expected timeframe. Once the line  10  stops, a new print string is sent to the printer  48 . This guarantees that the carton ID on the printer  48  and the controller  32  stay in sync. 
     Another option is to stop the line feed only. After triggering the printer  48 , the controller software waits for the acknowledgement and stops the line&#39;s feed unit  12  if the acknowledgement does not arrive in the expected timeframe. Once the feed stops, a new print string is sent to the printer  48 . The feed unit  12  can then be manually or electronically restarted. This guarantees that the carton ID on the printer  48  and the controller  32  stay in sync while minimizing disruption to production caused by a line shutdown. 
     Still another option is to Resync the line. After triggering the printer  48 , the controller software waits for the acknowledgement and attempts to resync with the printer  48  if the acknowledgement does not arrive in the expected timeframe. To resync, the controller  32  will send a new print string to the printer  48  and reject all cartons that pass the printer head until the printer  48  has acknowledged that it will begin using the new print string. 
     The final option is to take no action. This setting prioritizes line production and instructs the controller  32  to not stop the line  10  or feed unit  12  if a carton does not receive a printed string. With this setting, the controller  32  may end up out of sync. 
     The job start time is advantageously printed on the carton in a condensed format with as few characters as possible. The job start time is printed using the English alphabet. However, some characters of the alphabet are not used to make the string as readable and clear as possible, prevent look-alike characters, and prevent undesirable words from appearing in a global setting. The job start time is calculated as the number of seconds since an epoch in a 32-bit unsigned value. It is printed in base 24 with the following characters: {‘3’, ‘4’, ‘7’, ‘8’, ‘9’, ‘B’, ‘C’, ‘D’, ‘F’, ‘G’, ‘H’, ‘J’, ‘K’, ‘L’, ‘M’, ‘N’, ‘P’, ‘Q’, ‘R’, ‘T’, ‘V’, ‘W’, ‘X’, ‘Y’}. Using 6 characters in base 24 leads to 191,102,976 possible combinations. Using this methodology, the job start time value consists of a unique value for over six years from the date of printing. 
     The described system tracks whenever a system setting, or job setting is changed. The tracking information includes the first carton ID to pass the feed trigger after the change is made. When a customer wants to know the system and job settings associated with a carton, a range check is performed to determine the system and job setting information associated with a specific carton. This is done to optimize storage, since a machine may produce hundreds of thousands or even millions of cartons per day. Thus, even though a particular carton may not have data specifically associated with it, the information about how the carton was produced can be obtained because of the range check. 
     Because the carton data is stored in a remote database  42 , the carton does not need to be physically present in order to look up data about the carton. 
     For cartons that are rejected, a greater level of detail is needed, and they are tracked and stored individually. Several important details are stored for later display to a user, such as, but not limited to the carton ID printed on the carton; Associated job name and start time; Associated operator; Reason for rejection; The tolerance settings in use; All stations active at the time, and their configurations; Other controller functions, such as whether alarms were active or disabled, and other critical settings. 
     Thus, as described, the serialization allows a user to track carton production and trace issues that may arise subsequent to delivery of a carton. 
     The present invention has been described with respect to flowcharts and block diagrams. It will be understood that each block of the flowchart and block diagrams can be implemented by computer program instructions. These program instructions may be provided to a processor to produce a machine, such that the instructions which execute on the processor create means for implementing the functions specified in the blocks. The computer program instructions may be executed by a processor to cause a series of operational steps to be performed by the processor to produce a computer implemented process such that the instructions which execute on the processor provide steps for implementing the functions specified in the blocks. Accordingly, the illustrations support combinations of means for performing a specified function and combinations of steps for performing the specified functions. It will also be understood that each block and combination of blocks can be implemented by special purpose hardware-based systems which perform the specified functions or steps, or combinations of special purpose hardware and computer instructions. 
     It will be appreciated by those skilled in the art that there are many possible modifications to be made to the specific forms of the features and components of the disclosed embodiments while keeping within the spirit of the concepts disclosed herein. Accordingly, no limitations to the specific forms of the embodiments disclosed herein should be read into the claims unless expressly recited in the claims. Although a few embodiments have been described in detail above, other modifications are possible. For example, the logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. Other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Other embodiments may be within the scope of the following claims. 
     The foregoing disclosure of specific embodiments is intended to be illustrative of the broad concepts comprehended by the invention.