Robotic method and apparatus for removing parts from the trim press of a thermoforming system

An apparatus for removing a plurality of thermoformed parts from a trim press associated with a thermoforming process wherein the trim press is moveable between an open and closed position and is adapted to separate the thermoformed parts from a sheet of material which is fed through the thermoforming process and through the trim press, said apparatus comprising:

• a cutting tool associated with the trim press for completely severing the plurality of thermoformed parts formed within the sheet of material from the sheet of material when the trim press is in its closed position;
• a support structure mounted adjacent the trim press;
• a pick and place mechanism mounted to said support structure for movement into and out of the trim press;
• a plurality of orifices associated with the trim press for pulling a vacuum therethrough, said orifices being positioned and located so as to hold the severed thermoformed parts once the parts are severed from the sheet of material;
• vacuum means associated with the pick and place mechanism for engaging and holding the severed parts until removal from the trim press;
• and
• programmable controller means for controlling movement of the pick and place mechanism into and out of the trim press, movement of the pick and place mechanism being synchronized with the opening and closing of the trim press such that the plurality of severed thermoformed parts can be removed therefrom.

In a thermoforming system for forming a plurality of thermoformed articles from a sheet of thermoplastic material wherein said system includes a heater station for heating the sheet of material to its glass transition phase, a forming station where the sheet of material is formed into the specific shape of the articles being manufactured, and a trim press for removing the thermoformed articles from the sheet of material, the trim press being moveable between an open and closed position, the improvement comprising:

• a plurality of knife blades associated with the trim press for completely severing the plurality of thermoformed articles from the sheet of material when the trim press is in its closed position;
• a support structure positioned adjacent the trim press, said support structure including at least a pair of horizontal support members and at least a pair of vertical support members, a carriage member coupled to said horizontal and vertical support members, and a quick disconnect mechanism associated with said carriage member;
• a pick and place mechanism mounted to said quick disconnect mechanism for movement into and out of the trim press;
• a drive mechanism associated with some of said support members for moving said pick and place mechanism in at least a horizontal and vertical direction relative to said horizontal and vertical support members;
• vacuum means associated with the trim press for holding the severed thermoformed articles within the trim press until removed therefrom;
• vacuum means associated with said pick and place mechanism for capturing and holding the plurality of severed thermoformed articles when said pick and place mechanism is maneuvered into the trim press;
• and
• controller means for controlling movement of the pick and place mechanism into and out of the trim press, movement of the pick and place mechanism being synchronized with the opening and closing of the trim press.

A method for removing at least one molded part from a trim press associated with a thermoforming process wherein the trim press is moveable between an open and closed position and is adapted to separate the at least one molded part from a web of material used in the thermoforming process, said method comprising the following steps:

• maneuvering the web of material and the at least one molded part formed therein into the trim press;
• completely severing the at least one molded part from the web of material within the trim press;
• holding the at least one severed molded part within the trim press after the part is completely severed from the web of material and the trim press is moved to its open position;
• positioning a pick and place tool within the trim press for locating and acquiring the at least one thermoformed part;
• capturing and holding the at least one thermoformed part with the pick and place tool;
• removing the pick and place tool with the at least one thermoformed part engaged therewith from within the trim press;
• positioning the pick and place tool with the at least one thermoformed part engaged therewith at a location outside of the trim press;
• and
• releasing the at least one thermoformed part from the pick and place tool.

A method for removing at least one molded part from a trim press associated with a thermoforming process wherein the trim press is moveable between an open and closed position and is adapted to separate the at least one molded part from a web of material used in the thermoforming process, said method comprising the steps of:

• providing a cutting tool associated with the trim press, said cutting tool completely severing the at least one molded part from the web of material when the trim press is in its closed position;
• providing a support structure positioned adjacent the trim press;
• providing a pick and place mechanism mounted on said support structure;
• providing a drive system for moving and manipulating the pick and place mechanism within the trim press when the trim press is in its open position;
• providing holding means associated with the trim press for holding the at least one severed molded part within the trim press after severing occurs;
• providing holding means associated with the pick and place mechanism for capturing and holding the at least one molded part when the trim press is in its open position and when the pick and place mechanism is maneuvered adjacent the at least one severed molded part;
• and
• providing controller means for controlling movement of the pick and place mechanism into and out of the trim press, movement of the pick and place mechanism being synchronized with the opening and closing of the trim press such that the pick and place mechanism will engage and remove the at least one molded part from the trim press when the trim press is in its open position.

An method for removing a plurality of thermoformed parts from a trim press associated with a thermoforming process wherein the trim press is moveable between an open and closed position and is adapted to separate the thermoformed parts from a sheet of material which is fed through the thermoforming process and through the trim press, said method comprising the steps of:

• providing a cutting tool associated with the trim press for completely severing the plurality of parts formed within the sheet of material from said sheet of material when the trim press is in its closed position;
• providing a support structure mounted adjacent the trim press;
• providing a pick and place mechanism mounted to said support structure for movement into and out of the trim press;
• providing a plurality of orifices associated with the trim press for pulling a vacuum therethrough, said orifices being positioned and located so as to hold and acquire the severed thermoformed parts once the parts are severed from the sheet of material;
• providing vacuum means associated with the pick and place mechanism for engaging and holding the severed parts for removal from the trim press;
• and
• providing programmable controller means for controlling movement of the pick and place mechanism into and out of the trim press, movement of the pick and place mechanism being synchronized with the opening and closing of the trim press such that the plurality of severed thermoformed parts can be removed therefrom.

A method for removing a plurality of thermoformed articles from a trim press wherein said articles are formed from a sheet of thermoplastic material in a thermoforming system, the trim press being moveable between an open and closed position and being adapted for removing the thermoformed articles from the sheet of material, the method comprising the steps of:

• providing a plurality of knife blades associated with the trim press for completely severing the plurality of thermoformed articles from the sheet of material when the trim press is in its closed position;
• providing a support structure positioned adjacent the trim press, said support structure including at least a pair of horizontal support members and at least a pair of vertical support members, a carriage member coupled to said horizontal and vertical support members, and a quick disconnect mechanism associated with said carriage member;
• providing a pick and place mechanism mounted to said quick disconnect mechanism for movement into and out of the trim press;
• providing a drive mechanism associated with some of said support members for moving said pick and place mechanism in at least a horizontal and vertical direction relative to said horizontal and vertical support members;
• providing vacuum means associated with the trim press for holding the severed thermoformed articles within the trim press until removed therefrom;
• providing vacuum means associated with said pick and place mechanism for capturing and holding the plurality of severed thermoformed articles when said pick and place mechanism is maneuvered into the trim press;
• and
• providing controller means for controlling movement of the pick and place mechanism into and out of the trim press, movement of the pick and place mechanism being synchronized with the opening and closing of the trim press.