System for filling an open top box with packages

Abstract

 According to an aspect, a system (102) is disclosed for filling an open top box (121) with triangular prism shaped packages (105 - 109) comprising a first (401), second (402) and third (403) face. The system further comprising an infeed conveyor belt (114) adapted to supply the packages towards a flipping platform (113). The system comprising also a flipping platform (113) adapted to be arranged in a first and second position. This platform supports a set of packages by its first face (401) and exposes its third face when in this first position and supports this set by its second face (402) and exposes its first face (401) when in this second position. The system further comprising a robotic arm (101) comprising engagement means (103) adapted to releasably pick the set (104) from the flipping platform by the third face when in the first position, and by the first face when in the second position.

Description

Field of the Invention

[0001] The invention relates to the field of packaging systems. Such a packaging system comprises an input section, a robotic arm and an output section. The individual packages or goods are delivered to the robotic arm by the input section. The robotic arm then grips one or more packages, i.e., a set of packages and puts them in an open top box that is within range of the robotic arm at the output section. When the open top box is filled, it is transported away from the system and a new empty box is provided.

[0002] More particularly, the invention relates to the packaging of triangular prism shaped packages such as for example used for packaging triangular shaped sandwiches as found in supermarkets and gas stations.

Background of the Invention

[0003] Automated packaging is already widely adopted in industry, for example in logistic centres where goods or packages are packed together in boxes in an automated way. The boxes are then handled further and transported to customers. Turnkey solutions already exist that deliver packaging systems for packaging rectangular boxes or cuboids, often provided as carton boxes.

[0004] However, things get more complicated when the package have a non-cuboid shape. Then, the packages might have to be turned around and placed in a box according to a certain pattern in order to fill the box in the most economical way, i.e., by avoiding as much as possible empty space in the box.

[0005] In the patent application publication EP2465783 a machine for packaging yoghurt pots having a frustoconical shape with a trapezoid cross-section is disclosed. An auger is used to overturn a selection of the pots resulting in first row of non-flipped pots and a second row of flipped pots. In the patent application publication EP2500151 a complementary system is then disclosed that takes the pots from these two rows and groups them in order to deposit them at once in a carton.

[0006] A disadvantage of this combined system is that it is only applicable to frustoconical shapes with a trapezoid cross section such as for example yoghurt pots. Moreover, it is very complex involving multiple robots and actuators. It is however not usable for triangular prism shaped package which may for example be used as a package for triangular shaped sandwiches. Such a package is disclosed in the patent application publications US20040134810 and KR20100013105 and is also illustrated in Fig. 4. Due to the way these sandwiches are packed, these kind of packages may comprise a flap extending from one of the faces of the prism shape.

[0007] It is therefore an object of the invention to alleviate the abovementioned disadvantages and to provide a solution for packaging triangular prism shaped packages in a fast, flexible and economic way.

Summary of the Invention

[0008] This object is achieved, in a first aspect, by a system for filling an open top box with triangular prism shaped packages. These packages comprise a first and second triangular base and a first, second and third face. The system further comprises:

• An infeed conveyor belt adapted to supply the packages towards a flipping platform. The packages are positioned on this infeed conveyor belt with their triangular base vertical and with their first face on this conveyor belt.
• This flipping platform adapted to be arranged in a first and second position and comprising:

  o A bottom support adapted to accept a plurality of these packages from the infeed conveyor belt in this first position thereby forming a set of packages. The bottom support thereby supports this set by its first face and exposes the third face of the set. According to a particularly simple embodiment the bottom support is a horizontal fixed bottom plate.

  ○ A rotatable plate adapted to rotate together with the set from a position aligned with the second face of the set when in this first position to a position in which the rotatable plate supports the set by the second face and exposes the first face when in this second position.

• A robotic arm comprising engagement means adapted to:

  o Releasably pick the set from the flipping platform by its third face when in the first position and by its first face when in the second position.

  o Position and release the set in the open top box.

[0009] The robotic arm thus repeatedly picks a set and places it in the open top box. It picks such a set by any exposed side of the packages and thus of the set. If it needs to pick a set from the bottom face, the set is flipped, i.e., turned onto the previously standing second face. This way, what was the bottom face before becomes the exposed face and, hence, the robotic arm can pick the set by the now exposed face. So every package on the infeed conveyor may either be flipped or not depending which face needs to be gripped by the robotic arm.

[0010] The set may be picked from their third or first face, meaning that they are picked by the third face or first face of all the packages in the set. The sets are thus formed in the first position of the flipping platform by positioning the plurality of packages next to each other where the first base triangle of a first package is placed next and parallel to the second base triangle of a second neighbouring package in the set and so on. This way, the respective first, second and third faces of the packages form a single corresponding first, second and third face of the set, i.e. they form a single surface.

[0011] For the flipping or rotation of the set from the first to second position of the flipping platform, the rotatable plate is positioned against the second face of the set, i.e. against the second face of all packages in the set forming a single surface. If the triangular prism shaped package has a right angle triangle cross-section, the rotatable plate will be orthogonal to the fixed base support. As the set is rotated together with the rotatable plate, the first face of the set will be lifted from the fixed base support and thus be exposed after the rotation.

[0012] The robotic arm may for example be provided by a six axis industrial robot allowing a set of packages to be gripped from any side with every needed degree of freedom. Several means exist to releasably grip such a set by one of its faces. An example of such a means is a vacuum gripper with a plurality of vacuum suction cups. During the gripping, every suction cup that touches the respective face to be gripped will stick to it. If for example a set of two packages needs to be picked, one subset of the suction cups will grip the face of the first package and another subset of the suction cups will grip the face of the second package.

[0013] It is an advantage that a set can be gripped from the third or first face from the two positions of the flipping platform. This allows positioning the packages in the open top box with any of the faces facing downwards.

[0014] It is a further advantage that the flipping may or may not be done for any set. The flipping process is thus not restricted to a predefined repeating pattern. This allows gripping every single set by any desired face resulting in a very flexible way to fill any kind of open top box.

[0015] It is an even further advantage that the flipping platform works with a plurality of packages at once, i.e., with a set. This allows filling the open top box with several packages at once thereby considerably increasing the packaging speed as the robotic arm has to travel less distance compared with when packaging with one package at a time.

[0016] According to an embodiment, the rotatable plate further comprises a fixator for fixating a corner of the set defined by the second face and the third face during the rotating from the first position to the second position thereby holding the set against the rotatable plate.

[0017] In other words, if the flipping platform needs to rotate from its first to its second position, the fixator holds the upper corner, i.e., the corner between the second and third face of the set, against the rotatable plate. After the rotation, this fixator preferably releases this corner such that the set can be easily gripped by the robotic arm. As the fixator holds the corner of the complete set, the flipping is performed for the hole set. The fixator thus allows flipping the complete set at once.

[0018] According to an alternative or complementary embodiment of the fixator above, the rotatable plate further extends around said second face underneath said first face thereby partially supporting said set in said first position and during said rotation from said first position to said second position.

[0019] In this case, the rotatable plate thus comprises two parts under an angle which is the same as the angle between the second and first face. Because of this, the corner between the first and second face of the set is also fixated with the rotatable plate during the rotation.

[0020] This extension of the rotatable plate may be used without the fixator, but then it is preferred that the gravity point of the set in the first position of the flipping platform is located above this extension and not above the bottom support. As with the fixator, this extension allows flipping the complete set at once.

[0021] According to a preferred embodiment, the system further comprises:

• A blocker adapted to stop the packages on the infeed conveyor belt at a predetermined stopping position.
• A moving arm adapted to push the packages from this predetermined stopping position away from the conveyor belt onto the flipping platform.

[0022] In other words, every time a package arrives at this blocker it is pushed onto the flipping platform which is in its first position and, hence, the package is pushed onto the bottom support with its second face aligned and preferably in contact with the rotatable plate. Preferable, this pushing is performed substantially orthogonal to the moving direction of the belt. When a second package arrives at the blocker, it will be in the same orientation on the belt as was the previous package and will be pushed sideways onto the same flipping platform against the previous package. The two packages then touch each other by their triangular bases and their respective first, second and third face form the respective first, second and third face of the set. This way the set is formed. This pushing of packages is then repeated until the complete set is formed. Then the flipping platform stays in its first position or optionally rotates to its second position and the set is picked from the flipping platform with the robotic arm by its respective third or first face.

[0023] It is an advantage that by the moving arm and the blocker the packages are removed from the belt while at the same time forming the set.

[0024] It is a further advantage that the size of a set may be easily varied by changing the amount of packages or the width of the packages that are pushed onto the flipping platform before picking them with the robotic arm.

[0025] Optionally the packages further comprise a flap extending the third face beyond its first triangular base. The conveyor belt is further configured to carry the packages with the third face first. The moving arm is further configured to push a first package of the set against the first base triangle in a direction substantially orthogonal to the conveyor belt just until the first face is no longer on the conveyer belt. The conveyer belt is further adapted to guide a second package of the set up to the blocker such that the third face of the second package is partially under and against the flap of the first package. The moving arm is further configured to push the first and second package together onto the flipping platform by pushing against the first base triangle of the second package.

[0026] These flaps are typically used for the sealing of food inside these triangular prism shaped packages, e.g. for sealing triangular sandwiches in a sandwich package. They also serve as a lip to easily remove the seal from the package. In order to form the sets, the flap of one package needs to overlap with the equivalent face of the neighbouring package otherwise excess space may be left between the upstanding triangular bases of neighbouring packages in a set.

[0027] By pushing the first package of a set onto the flipping platform but leaving the extending flap still in the track of the conveyer belt, the next package arrives nicely under and against this flap. This principle may be repeated for sets with more than two packages.

[0028] According to an embodiment, the robotic arm is further configured to:

• Releasably pick a first set of the packages from the flipping platform in the first position by its third face.
• Put this first set in the open top box with the first face of the first set on a bottom floor of the open top box.
• Releasably pick a second flipped set of the packages from the flipping platform in its second position by the first face.
• Put the second set on top of the first set in the open top box with the first face of the second set facing upwards and the third face of the first and second set contacting each other over their full surface.

[0029] This allows packaging the triangular prism shaped packages in an economical way. For example, if the package is a right angled triangular prism with the longest edge defining the third face, then the first and second set together will form a rectangular box. These steps may be repeated by the robotic arm in order to completely fill a box.

[0030] According to an embodiment the open top box further comprises left and right side walls vertically attached to the bottom floor and left and right top covers parts in the top surface of the box respectively attached to the left and right side walls. The base faces of the packages further corresponding to a substantially right-angled triangle. The cross-section of the first and second set together placed in the open top box parallel to the base faces thereby corresponding to a right angled rectangle. After putting the first and second set in the open top box, the second face of the first set is parallel and closest to the left side wall. According to this embodiment the robotic arm is then further configured to:

• Push the first and second set together against the left side wall under the left top cover parts by pushing against the second face of the second set thereby leaving an empty space in the open top box substantially equal to a space occupied by the first and second set together.
• Releasably pick a third set of packages from the flipping platform in its first position by the third face.
• Put the third set downwards in a final position in the box whereby the second face of the third set is against the second face of the second set and the first face of the third set is on the bottom floor.

[0031] The top cover parts of the box may reinforce the box and make it easier to put a plurality of these boxes on top of each other. By filling the box in this way it allows turning the box on its left side without the packages sliding out of the box. This may be done in a shop to present the packages without taking them out of the box.

[0032] This putting the third set may comprise the following steps performed by the robotic arm:

• Rotate the third set clockwise according to the final position before passing the top surface allowing passage beyond the right top cover part.
• Rotate the third set counter clockwise back to the final position when the third set has passed beyond the top surface.

[0033] This way the third package may pass through the opening in the box which is smaller than the first face of the package while the robotic arm grips the package by the top side, i.e., by the third face.

[0034] According to a further embodiment, the system comprises a plurality of infeed conveyor assemblies each comprising such infeed conveyor belt and flipping platform. The robotic arm is then further configured to releasably pick the set from any one of said plurality of such infeed conveyor assemblies.

[0035] This allows to package a box even faster. It allows gripping packages from one flipping platform while in the meantime a new set is formed on the other flipping platform.

[0036] According to a second aspect, the invention relates to a method for filling an open top box with triangular prism shaped packages. These packages comprising a first and second triangular base and a first, second and third face. The method comprising the following steps:

• Positioning the packages on an infeed conveyor belt with the triangular base vertical and with the first face on the conveyor belt.
• Supplying the packages towards a flipping platform with the infeed conveyor belt.
• The flipping platform accepting a plurality of the packages on a bottom support from the infeed conveyor belt according to a first position of the flipping platform thereby forming a set of packages and thereby supporting the set by the first face and exposing the third face of the set.
• Rotating a rotatable plate of the flipping platform together with the set from a position aligned with the second face of the set when in the first position to a position in which the rotatable plate supports the set by the second face and exposes the first face corresponding to a second position of the flipping platform.
• Releasably picking the set from the flipping platform with a robotic arm by the third face when in the first position, and by the first face when in the second position.
• Positioning and releasing the set in the open top box.

Brief Description of the Drawings

[0037] 

Fig. 1 a) illustrates a top view of a packaging system according to an embodiment of the invention; and

Fig. 1 b) and c) illustrate a side view of an infeed conveyor assembly according to an embodiment; and

Fig. 2 illustrates a flipping platform rotating a set of packages from a first position to a second position; and

Fig. 3 illustrates an arrangement of an infeed conveyor belt and moving arm to form sets of triangular prism shaped packages; and

Fig. 4 illustrates an triangular prism shaped package with a flap as known in the art; and

Fig. 5 illustrates a sequence to package right angle triangular prism shaped packages in an open top box with a packaging system according to an embodiment of the invention; and

Fig. 6 illustrates a further sequence to package right angle triangular prism shaped packages in an open top box with a packaging system according to an embodiment of the invention; and

Fig. 7 illustrates a packaged open top box filled with packages in different positions; and

Fig. 8 illustrates a packaging system with two infeed conveyor assemblies according to an embodiment of the invention.

Detailed Description of Embodiments

[0038] The embodiments below describe a packaging system for packaging triangular prism shaped packages. Such packages are for example often used as a package for triangular shaped sandwiches and are typically sold in super markets or gas stations. Some terms used to define such a package will first be explained with reference to Fig. 4. These terms will further be used systematically in the description of the various embodiments below. In Fig. 4, a single triangular prism shaped package 400 is shown. The package comprises two triangular faces 405 and 406 further referred to as the bases of the package 400. The three legs 115, 116 and 117 of both triangles 406 and 405 define the three respective faces 403, 401 and 402. The longest face 403 is further referred to as the third face 403. The bottom face 401, i.e., the face on which the package is placed when provided to the packaging system, is further referred to as the first face 401. The standing face 402 is further referred to as the second face 402. When the triangular prism is a right angle triangle, then the longest edge or hypotenuse of the triangle defines the third or longest face 403.

[0039] Optionally, such a triangular prism shaped package 400 may comprise a flap 404, i.e. one of the faces 401, 402 or 403 extending over one of the bases 405 or 406. As this kind of packages are typically for packaging fresh food products such as for example triangle shaped sandwiches, the extending flap 404 may be a result of the packaging of the sandwich itself whereby at the end one face is adhered to the other faces and bases of the prism. The flap may also be used as a means to remove the seal of the package, i.e., to open the package 400. In the example of Fig. 4, the flap 404 is extending from the long or third face 403 over the base face 405.

[0040] Fig. 1 illustrates a packaging system 102 according to an embodiment of the invention. The system 102 comprises an infeed conveyor assembly 100 to bring triangular prism shaped packages 105 till 109 as also shown in Fig. 4 towards the robotic arm 101. The packages are fed into the system 102 by an infeed conveyor belt 114 that provides the packages along a direction 118 towards a stopper in the form of a bar 111.

[0041] As shown in Fig. 1-b) and Fig. 1-c), representing a side view of the input conveyor assembly, the packages are positioned on the belt 114 such that a first face 401 of the triangular prism is on the belt, a second face 402 is trailing and a third face 403 is leading with respect to the moving direction 118 of the belt 114. The two bases of the triangular prism are then positioned vertical and parallel to the moving direction 118 of the belt 114. As shown, the packages are thus supported by means of their first face 401 on the belt 114.

[0042] The bar 111 is positioned just above the conveyor belt 114. The packages then bump into the bar 111 with the third face 403 at the corner line 125 of the third face 403 and first face 401. When a package is stopped at the bar 111, a moving arm 110 pushes the respective package away from the belt 114 onto a flipping platform 113 according to the direction 112 where a set 104 of packages is formed. As shown, according to this embodiment the direction 112 is substantially transvers to the moving direction 118.

[0043] Depending on the specific configuration a set may comprise one or more packages. In Fig 1-a) a set 104 of two packages 108-109 is formed on the flipping platform 113. Thus after the package 109 is pushed onto the platform 113, the next package 108 arrives at the bar 111 and is also pushed onto the platform 113. As the package 109 is already on the platform 113, it shifts also along the direction 112 when the next package 108 is pushed onto the platform 113. This way a set 104 is created whereby the packages in a set touch each other by a base face.

[0044] When a set 104 is formed on the flipping platform 113, the third face 403 of the packages and thus of the set faces upwards. This is the first position of the flipping platform 113 as illustrated in Fig. 1-b). The flipping platform may also rotate backwards along the direction 122 into a second position as illustrated in Fig. 1-c). In this second position, the first face 401 becomes exposed.

[0045] A robotic arm 101 then picks sets 104 from the flipping platform 113. This picking is done by gripping the set 104 at an exposed face, i.e., either the face 403 when the flipping platform is in the first position or face 401 when the platform is in the second position. By being able to grip packages either from the long or third face 403 or the short bottom or first face 401, the packages may be put in the open top box or container 121 in an easy and straightforward manner.

[0046] Fig. 5 illustrates how the robotic arm 101 may put right angled prism shaped packages 520 and 519 in an open top container 521 by gripping the packages from both the long top face 403 and the bottom face 401 as provided by the embodiment of Fig. 1. First the robotic arm 101 grips the package 520 by the third face 403 from the flipping platform 113 in its first position. The robotic arm 101 brings the package 520 vertically along the direction 501 into the open top container 521, as shown in Fig. 5-a). It then places the package 520 onto the bottom floor 522 of the open top container 521 as shown in Fig. 5-b). Then, as illustrated by Fig. 5-c), the robotic arm places the second package 519 reversely on top of the first package such that the long faces 403 of the two packages 519 and 520 contact each other over their whole face. Again, as shown, this is performed by a vertical movement 503 of the robotic arm 101. Due to the fact that only the top part of the container 521 is open, the robotic arm must grip the package 519 from its top face when it would be in its desired position, i.e. from the first face 401. Therefore, the robotic arm will grip the package 519 form the flipping platform 113 in its second position exposing the first face 401. In this configuration, the two packages 519 and 520 have a rectangular cross section and are thus packaged in a place saving manner within the container 521. The steps according to Fig. 5-a) till Fig. 5-c) may be repeated in order to fill an open top box with packages.

[0047] The open top box 530 may further comprise small portions 530 and 531 extending inwards the box within the top surface plane. These extending portions are widely used for reinforcement of the box and for stacking boxes on top of each other. When boxes are stacked, the top box is then supported by these reinforcing extensions 530 and 531, also referred to as top cover parts 530 and 531. If these reinforcing extensions would not be present, the box on top would only be supported by the side wall of the box below. A small misalignment of the two boxes would cause the box on top to partially fall inside the box below which is an undesirable effect. The reinforcing extensions may for example be provide on all sides of the box or only on two sides as illustrated by Fig. 5 where the reinforcing extensions are only present at the left and right side walls 533 and 532 of the box 521. The reinforcing extensions may be present along a complete wall of the box but also only in the corners as a small triangular or rectangular piece fitted between and on top of two adjacent walls of the box 521.

[0048] Fig. 6 illustrates further steps performed by the robotic arm 101 to fill a box comprising such reinforcing extensions 530 and 531 according to an embodiment. Due to the reinforcing extension 530, the first and second sets of packages 520 and 519 cannot be place underneath the reinforcing extension 530. Therefore, after the sets have been vertically positioned in the box according to Fig. 5-c), the robotic arm 101 pushes the two sets 520 and 519 together against the first wall of the second package 519 along the direction 610 underneath the reinforcing extension 530. Then, the robotic arm takes a third set of packages 617 from the flipping platform 113 in its first position by the third face 403 of the set. The set 617 is then positioned in a vertical direction 613 into the box 521.

[0049] The place 611 left in the box 521 at the right of the sets 520 and 519 may be substantially the same as the place 618 already taken by the sets 520 and 519. In this case, it may be impossible to position the set 617 in the box by a single vertical movement 613 because of the reinforcing extension 531 extending from the right wall 532 of the box. To alleviate this, the robotic arm rotates the set 617 in a clockwise direction 614 according to its final desired position in the box before the first face 401 of the set 617 passes the top surface 612 of the box 521. By this rotation, the horizontal cross-section of the set 617 is smaller than the opening left in the top of the box. After or during the clockwise rotation 614, the robotic arm 101 passes the set 617 beyond the top surface 612 by moving the set 617 in a downward direction 613 in the box 521. After the set 617 has at least partly passed the top surface 612, the set 617 is rotated in a counter clockwise direction 615 to be in its desired orientation. It is then also positioned downwards 616 with its first face 401 onto the bottom floor 522 of the box 521.

[0050] The positioning of sets in an open top box with reinforcing extensions may be performed for any size of box and thus for any number of sets. When a box 521 has a width of two sets, i.e., of two times the first leg of a set, it may be filled according to the steps performed in Fig. 5 and Fig. 6. A configuration as illustrated by Fig. 7-a) will then be obtained. This configuration has the advantage that the box 521 may be placed in an upright position without the package falling out of the box as illustrated by Fig. 7-b). As shown, the set 520 is stable on itself. Set 519 would normally slip out of the box 521 diagonally along the third face of the set 520 but is held in place by the reinforcement extension 530. Set 617 is again in a stable position by resting on its second face 402. A filled box may for example be put in such an upright position when displaying the packages in a shop. This way, the package do not have to be removed from the box.

[0051] Other configurations for filling an open top box or container with or without reinforcing extensions are also possible. For example, longer containers may be filled by putting three sets on the bottom with none to three sets reversely on top or by putting four sets on the bottom with none to four sets reversely on top.

[0052] Referring to both Fig.1 and Fig. 5, the robotic arm 101 is equipped with engagement means 103 for gripping the packages from the flipping platform 113 and for releasing the packages in the open top container 121, 521. This engagement means 103 may for example be a gripper with vacuum suction cups large enough to cover the faces of all packages in a set as known in the art. When gripping a set, each suction cup will attach to one of the exposed faces of the packages guaranteeing that the complete set is picked up by the robotic arm 101.

[0053] Fig. 2 illustrates a flipping platform 113 according to an embodiment. The flipping platform 113 comprises a fixed horizontal support 201. Onto this support 201, the packages 108 and 109 are pushed by the moving arm 110 of Fig. 1-a) in order to form the set 104. It also comprises a vertical support 202 against which the second face 402 of the package and thus the set is positioned when the platform is in its first position as illustrated by Fig. 2-a). In this first position, the robotic arm 101 may grip the package by its third or long face 403. When the set 104 needs to be gripped by the first face 401, the platform 113 needs to be rotated to the second position. Before the rotating 205, a fixator 203 which is assembled onto the vertical support 202 fixates the upper corner 210 of the set 104, i.e. the corner defined by the second face 402 and third face 403. This is accomplished by vertically moving along the direction 211 a fixating part 204 onto the corner 210. When the corner 210 is fixed, the support 202 rotates away from the fixed horizontal support 201 in the direction 205. This rotation as shown in Fig. 2-b) is performed around the corner 212 defined by the second face 402 and first face 401 until the support 202 is substantially horizontal thereby exposing the bottom face 401. After the rotation 205, the fixating part 204 is retracted 213 from the upper corner 210. When the fixator 203 has released the set 104, the set 104 may be picked up by the robotic arm by gripping the first face 401.

[0054] In order to hold the set firmly during the rotation, the rotatable plate 202 may further comprise an extension 220 that sits under the first face 401 of the set 104 when the flipping platform is in its first position. This extension 220 will prevent the set 104 from sliding of the rotatable plate 202 in the beginning of the rotation 205. Such sliding will not influence the flipping of the set 104 as long as the fixating part 204 is made large enough. With this extension 220, the rotation 205 may this be performed more accurately.

[0055] Alternatively, the extension 220 may be made so large that the fixator 203 is no longer needed. To establish a rotation without fixator, the extension should at least extend beyond the centre of gravity of the set 104. On the other hand, the extension should be limited such that it does not cover the complete first face 401 of the set.

[0056] As shown, the bottom support 201 is a fixed horizontal bottom plate onto which the packages slide by the movement of the moving arm 110. Alternatively, the support 201 it may also be another conveyor belt or roller track that allows moving the set in a predetermined direction before the flipping.

[0057] The triangular prism shaped packages may further comprise a flap 404 as illustrated in Fig. 4. A problem with such a flap is that the forming of a set 104 on the flipping platform 113 may fail. This is because the packages 108 and 109 are stopped by the bar 111 at the exact same position. When the moving arm 110 pushes the second package 108 against the first package 109, the flap of the first package 109 will obstruct the second package such that the bases of the packages will not be in contact with each other. This causes an empty space between the two packages 108 and 109 of the set.

[0058] Fig. 3 illustrates the infeed conveyor assembly according to a further embodiment alleviating this shortcoming. There, the infeed conveyor belt is arranged in such a way that the packages 108-109 arrive against the bar 111 with the right base face 406 at the side of the conveyor belt 114, i.e., just not onto the flipping platform 113. In the embodiment of Fig. 3 this is accomplished by a guiding bar 303. Then, when the first package 109 arrives it is pushed by the moving arm 110 onto the flipping platform 113 such that the left base face 405 of the package 109 is on the platform, but the flap 404 still extends onto the conveyor belt 114. Then, the next package 108 is brought to the bar 111 by the conveyor belt 114. By means of the guide 303, the front or third face 403 of this package 108 arrives under and against the flap 404 or the previous package 109. The moving arm 110 then pushes the packages 108 and 109 together further onto the flipping platform 113. Depending on the amount of packages in a set, this process may be repeated for the further packages in the set. When the set is complete the moving arm 110 may push the complete set further onto the flipping platform 113 for gripping by the robotic arm or for flipping it into the second position.

[0059] Fig. 8 illustrates a packaging system 802 according to an embodiment of the invention. In this embodiment, the system disclosed by Fig. 1 further comprises a same second infeed conveyor assembly 800 further comprising a second infeed conveyer belt 814, a second moving arm 810, a stopping bar 811 and a second flipping platform 813. This second conveyor belt 814 brings package 805, 806 and 807 towards the flipping platform 813 on which a set 804 with packages 808 and 809 is formed by the moving arm 810. The robotic arm 101 may then pick the sets 104, 804 from any of these assemblies. This may for example be done in an alternating way whereby sets are alternatingly picked from the first 100 and second 800 infeed conveyor assembly. By having a plurality of infeed conveyor assemblies, the packaging speed may be increased as more sets may be prepared for picking by the robotic arm 101 within the same time frame.

[0060] Although the present invention has been illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied with various changes and modifications without departing from the scope thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. In other words, it is contemplated to cover any and all modifications, variations or equivalents that fall within the scope of the basic underlying principles and whose essential attributes are claimed in this patent application. It will furthermore be understood by the reader of this patent application that the words "comprising" or "comprise" do not exclude other elements or steps, that the words "a" or "an" do not exclude a plurality, and that a single element, such as a computer system, a processor, or another integrated unit may fulfil the functions of several means recited in the claims. Any reference signs in the claims shall not be construed as limiting the respective claims concerned. The terms "first", "second", third", "a", "b", "c", and the like, when used in the description or in the claims are introduced to distinguish between similar elements or steps and are not necessarily describing a sequential or chronological order. Similarly, the terms "top", "bottom", "over", "under", and the like are introduced for descriptive purposes and not necessarily to denote relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and embodiments of the invention are capable of operating according to the present invention in other sequences, or in orientations different from the one(s) described or illustrated above.

Claims

1. A system (102, 802) for filling an open top box (121, 521) with triangular prism shaped packages (105 - 109, 400, 119, 120, 519, 520, 617, 805-809); said packages comprising a first (405) and second (406) triangular base and a first (401), second (402) and third (403) face; said system further comprising:

- an infeed conveyor belt (114) adapted to supply said packages towards a flipping platform (113); and wherein said packages are positioned on said infeed conveyor belt (114) with said triangular base (405) vertical and with said first face on said conveyor belt;

- said flipping platform (113) adapted to be arranged in a first and second position and comprising:

o a bottom support (201) adapted to accept a plurality of said packages from said infeed conveyor belt in said first position thereby forming a set (104) of packages, thereby supporting said set (104) by said first face (401) and exposing said third face of said set;

o a rotatable plate (202) adapted to rotate together with said set from a position aligned with said second face of said set when in said first position to a position in which said rotatable plate (202) supports said set (104) by said second face (402) and exposes said first face (401) when in said second position;

- a robotic arm (101) comprising engagement means (103) adapted to:

o releasably pick said set (104) from said flipping platform by said third face when in said first position, and by said first face when in said second position; and

o position and release said set (104) in said open top box (121, 521).

2. A system according to claim 1 wherein said rotatable plate (202) further comprises a fixator (203) for fixating a corner of said set defined by said second face (402) and said third face (403) during said rotating from said first position to said second position thereby holding said set against said rotatable plate (202).

3. A system according to claim 1 wherein said rotatable plate further extends (220) around said second face underneath said first face thereby partially supporting said set in said first position and during said rotation from said first position to said second position.

4. A system (102, 802) according to any one of the preceding claims further comprising:

- a blocker (111) adapted to stop said packages on said infeed conveyor belt (114) at a predetermined stopping position; and

- a moving arm (110) adapted to push said packages from said predetermined stopping position away from said conveyor belt (114) onto said flipping platform.

5. A system (102, 802) according to claim 4 wherein said packages further comprise a flap (404) extending said third face (403) beyond said first triangular base; and wherein said conveyor belt is further configured to carry said packages with said third face first; and wherein said moving arm (110) is further configured to push a first package (109) of said set against said first base triangle (405) in a direction orthogonal to said conveyor belt just until said first face (401) is no longer on said conveyer belt; and wherein said conveyer belt (114) is further adapted to guide a second package (108) of said set (104) up to said blocker (111) such that said third face (403) of said second package (108) is partially under and against said flap (404) of said first package; and wherein said moving arm (110) is further configured to push said first and second package together onto said flipping platform (113) by pushing against said first base triangle (405) of said second package (108).

6. A system (102, 802) according to any one of the preceding claims wherein said robotic arm is further configured to:

- releasably pick a first set (520) of said packages from said flipping platform in said first position by said third face (403); and

- put said first set (520) in said open top box (521) with said first face of said first set on a bottom floor (522) of said open top box; and

- releasably pick a second set (519) of said packages from said flipping platform in said second position by said first face; and

- put said second set (519) on top of said first set in said open top box with said first face of said second set facing upwards and said third face of said first and second set contacting each other over their full surface.

7. A system (102, 802) according to claim 6 wherein said open top box (521) further comprises left (533) and right (532) side walls vertically attached to said bottom floor (522) and left (530) and right (531) top covers parts in the top surface (612) of said box (521) respectively attached to said left (530) and right (531) side walls; said base (405, 406) faces of said packages corresponding to a substantially right-angled triangle; a cross-section of said first and second set together in said open top box parallel to said base faces thereby corresponding to a right angled rectangle (617); and after said putting said first (520) and second (519) set, said second face of said first set (520) is parallel and closest to said left side wall (533); and wherein said robotic arm (101) is further configured to:

- push said first and second set together against said left side wall (533) under said left top cover parts (530) by pushing against said second face of said second set (519) thereby leaving an empty space (611) in said open top box substantially equal to a space (617) occupied by said first and second set together; and

- releasably pick a third set (617) of said packages from said flipping platform in said first position by gripping said third face (403) of said third set (617); and

- put said third set (617) downwards (613, 616) in a final position in said box whereby said second face of said third set is against said second face of said second set and said first face of said third set is on said bottom floor.

8. A system according to claim 7 wherein said putting said third set further comprises:

- rotate (614) said third set (617) clockwise according to said final position before passing said top surface (612) allowing passage beyond said right top cover part (531);

- rotate (615) said third set counterclockwise back to said final position when said third set has passed beyond said top surface (612).

9. A system (802) according to any one of the preceding claims wherein said system comprises a plurality (100, 800) of infeed conveyor assemblies each comprising such infeed conveyor belt (114, 814) and flipping platform (113, 813); and wherein said robotic arm (101) is further configured to releasably pick said set (104, 804) from any one of said plurality of such infeed conveyor assemblies (100, 800).

10. A method for filling an open top box (121, 521) with triangular prism shaped packages (105 - 109, 400, 119, 120, 519, 520, 617); said packages comprising a first (405) and second (406) triangular base and a first (401), second (402) and third (403) face; said method comprising the following steps:

- positioning said packages on an infeed conveyor belt (114) with said triangular base (405) vertical and with said first face on said conveyor belt;

- supplying said packages towards a flipping platform with said infeed conveyor belt (114);

- said flipping platform accepting a plurality of said packages on a bottom support (201) from said infeed conveyor belt according to a first position of said flipping platform thereby forming a set (104) of packages and thereby supporting said set (104) by said first face (401) and exposing said third face of said set;

- rotating a rotatable plate (202) of said flipping platform together with said set from a position aligned with said second face of said set when in said first position to a position in which said rotatable plate (202) supports said set (104) by said second face (402) and exposes said first face (401) corresponding to a second position of said flipping platform;

- releasably picking said set (104) from said flipping platform with a robotic arm by said third face when in said first position, and by said first face when in said second position; and

- positioning and releasing said set (104) in said open top box (121, 521).

Drawing