Note: Descriptions are shown in the official language in which they were submitted.
CA 02490461 2004-12-14
AUTOMATIC COVER APPLICATOR
10
BACKGROUND OF THE INVENTION
~0004~ Large heavy industrial products often comprise natural materials such
as composite
is materials, engineered wood products, lumber, prefabricated engineering
products, building
construction materials, and the like. These materials are often packaged and
shipped in open
boxlike crated forms. It is important that such products be protected from
damage during
shipping and handling. Often damage can occur to the ends and comers of such
material, For
example, products such as stacks of plywood or composite particle board can
sustain damage
2o during shipping to any exposed areas of the stack but corners and edges are
most prone to
chipping or other damage as a result of transportation and handling. Damage to
edges and
corners of stacked building materials is unacceptable to retailers and renders
the damaged
product pieces unmarketable.
25 ~ooos~ Moisture control has also been a concern with such products and
several devices exist
for wrapping product with plastic material. Wrapping, however, does not
eliminate or reduce
the potential for physical damage to the ends, sides, surtaces and edges of
stacked wood or
composite products.
30 BRIEF SUMMARY OF THE INVENTION
In one aspect of the invention, an applicator apparatus is provided which
applies a
protective cover to a product such as a stack of flat sheets of building
material. A platform
supports the product in a predetermined orientation. Adjacent the platform is
a frame which
supports a cover manipulator. The cover manipulator is mounted on a transport
on the frame
35 and operates to grasp a protective cover from a cover magazine. The
transport mechanism is
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operable to move the cover manipulator from a position adjacent the cover
magazine to a
second position adjacent the platform. The applicator then presses the cover
against the
product in a predetermined orientation and a fastening mechanism secures the
cover to the
product. Typically, the cover is a flat sheet of cardboard or similar
protective material. The
material has scored or relieved portions which permit its top and ends to be
folded over the
end of the product to which it is applied. The material may then be rotated on
a platform
adjacent the frame so that another cover can be applied to the opposite end.
The foregoing and other objectives, features and advantages of the invention
will be
io more readily understood upon consideration of the following detailed
description, taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL DRAWINGS
FIG. 1A is a top schematic view of a material handling system which includes a
cover
i5 applicator apparatus.
tooos~ FIG. 1B is a side elevation view of the apparatus of FIG. 1A.
FIG. 2 is an end view taken along line A of FIG. 1A.
zo
FIG. 3 is a side elevation view taken along line B of FIG. lA.
FIG. 4 is a partial rear view of a folding and fastening mechanism attached to
a
protective cover prior to its afFxation to a package of material.
FIG. 5 is a partial rear view of the apparatus of FIG. 4 with the cover folded
over and
attached.
FIG. 6 is a side elevation view of a second embodiment of a protective cover
applicator
so apparatus.
FIG. 7A is a partial side view of a rotating turntable for positioning product
for the cover
applicator apparatus.
~oois7 FIG. 7B is a partial side view of the apparatus of FIG. 7A with the
turntable lifted and
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' CA 02490461 2004-12-14
partially rotated.
FIG. 8 is a partial side cutaway view of the apparatus of FIG. 1 taken along
line C.
~oo~s~ FIG. 9A is a top sectional view of a moving cage which forces a
protective cover to fold
over portions of the top, end and sides of a product.
FIG. 9B is a front view of the cage of FIG. 9A.
io coom FIG. 9C is a sectional side view of the cage of FIG. 9A.
coon FIG. 9D is a side view of a form of the protective cover to be folded
onto the product
by the cage of FIGs. 9A-C.
~aoz27 FIG. 10 is a block schematic diagram of a control system for
automatically operating the
apparatus of FIGs. 1A and 1B.
FIG. 11 is a side elevation view of third embodiment of an applicator
apparatus for
applying a protective cover to a product.
FIG. 12 is a partial front view of the apparatus of FIG. 11.
FIG. 13 is a partial side elevation view of a magazine for holding a stack of
protective
covers.
FIG. 14 is a partial side elevation view showing the protective cover
applicator of FIG.
11 in actual operation.
FIG. 15 is a side elevation view of the protective cover applicator of FIG. 14
with the
3o cover pressed against the product.
coo~ai FIG. 16 is a side elevation view of a protective cover applicator of
FIG. 14 with the
cover folded over the ends of the product.
~00~7 FIG. 16A is a front view of the protective cover applicator of FIG. 16.
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FIG. 17 is a partial top view of the protective cover applicator of FIG. 16.
FIG. 18 is a partial side view of the protective cover applicator of FIG. 11
illustrating the
s operation of the rotary turntable supporting the product.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Referring to FIGS. lA and 1B, a system for inspecting, protective cover
application and
banding large and heavy industrial products typically in rectangular boxlike
form is illustrated.
io The system employs a powered conveyor assembly 1 to move a product along a
path so as to
enter workstations for visual inspection 15, cover application 13 and banding
6 of the product
for ease of handling, protection and transporting. The visual inspection 15
workstation consists
of at least two polarized light illumination devices 2 and at least two line-
scan video cameras
17. The video cameras 17 provide images of the product 16 side and edge
surfaces for a
is means of allowing the operator to remotely view and detect the presence of
product damage
before application of covers. Depending upon the type of product additional
cameras may be
integrated into the system for means of examining the product 16 upper surface
and leading
and trailing end surfaces. The images obtained for each individual product 16
are also
transmitted to a computer controlled image storage and retrieval system. This
image storage
zo and retrieval system provides a means of providing evidence as to the state
of the product
before it was shipped and received by the customer.
In its simplest form, the cover application 13 workstation receives a product
16 in a
generally precise location and orientation to the automated cover installer
18. Accurate
is positioning of the product 16 is obtained through an arrangement of
electronic position sensors
4 and mechanical devices, which guide and force the paralleling of all sides
and ends of the
product 16. The height of the product 16 is also determined by a combination
of electronic
and mechanical means so as to provide further accurate alignment with cover
installer 18. The
cover installer transport 11 is a powered assembly of guides, slides and
rollers, which traverse
3o along path 9. The cover installer transport 11 also serves to raise and
lower the integrally
attached cover installer 18 and cover holder 19. The cover installer transport
il provides the
means moving cover installer 18 to a supply of covers 12 and then manipulate
cover holder 19
for retrieving a new cover 12 and then moving cover installer 18 to the side
of product 16 to
engage cover holder 19 and attach the cover 12. Having attached a cover 12 to
one side,
ss installer transport 11 moves to obtain another new cover 12 from the
source. During this
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CA 02490461 2004-12-14
operation x-y table 3, adjustable between 0 and 360 degrees in increments, is
energized and
rotates product 16 180 degrees so as to place the product's uncovered side
ready to receive a
cover 12. Because the cover applicator 13 workstation is constructed in
modular form it is
therein possible to attach and arrange additional modules for means of
attaching covers to the
opposite side as well as to the top sun'ace, front and rear sun'aces of the
product 16 when
greater through-put and productivity is desired. This operation is performed
in an automated
and sequenced operation.
The product banding 6 workstation serves to further process the now covered
product
io by banding it with locking straps 7 for means of restraining any movement
of the articles,
which comprise the product 8. The banding 6 workstation also creates a label
and/or tag
which identifies the contents and condition of the product obtained from the
electronic visual
inspection records stored in the a computer and obtained previously from the
visual inspection
15 workstation. Sensors 5 and 10 serve to detect the movement and location of
the product
15 has it enters and leaves the workstation.
The arrangement of the visual inspection 15, cover installation 13 and banding
6
workstation, along a common and shared conveyor 1 provide a logical order in a
sequence of
operations necessary in concluding the packaging of a product before it is
shipped to a
2o customer. No one operation can be omitted. It also possible to extend the
distance between
workstations, while using a common and shared conveyor, to accommodate for
available space
within a facility or for closer Proximity to other workstations in the
manufacturing process of
the product. It is also further possible to separate one or more workstation
from the common
and shared conveyor and employ some other form of conveyance device to move
the product
z5 from workstation to workstation where distance prohibits close proximity of
workstations.
Referring to FIG. 2 is a cross-section illustration, as identified in FIG. 1
by A, of the
visual inspection workstation. The product 22 is entered into the field of
illumination provided
by tamps 20 and view of video cameras 21 by powered conveyor 24. At least one
sensor 23 is
so used to detect the entry and exist of the product 22 into the workstation.
Sensing entry into
the workstation the sensor 23 initiates energizing lamps 20 and video cameras
21. As the
product moves through the workstation image information from both sides of the
product 22 is
transmitted to a central processing unit where it is simultaneously stored and
identified by a
product article number, date and time. The image information is also presented
to the system
s5 operator through a computer monitor for means of examining the product for
possible
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damage. To enhance visual detection polarized light and the angle of
illumination are
controlled so as to reduce reflection and improve the definition of product
defects and damage.
When greater definition and resolution is required for detecting product
defects several video
cameras 21 and illuminators 20 can be arranged to provide a 3-dimension image
using
s computer software applications. Additional cameras may also be included to
examine the
front, rear and upper surfaces of the product. To meet a variety of inspection
requirements
peculiar to various types of products still imaging, line scan and motion
video imaging may be
combined in various arrangements. Ultraviolet and Infrared illumination in
combination with
respective types of imaging systems may also be employed for inspecting
special types of
io products.
Referring to FIG. 3 is a cross-section illustration, as identified in FIG. 1
by 13, of the
cover applicator workstation. The cover applicator serves to attach protective
covers to the
sides, ends and upper surface of a rectangular box like shaped product. There
are many forms
i5 and configurations of covers the cover applicator is adapted to installing
and attaching to
products. A product entering into the cover applicator workstation is detected
by sensor 37,
which serves to determine its length, and initiates a signal to an electrical-
mechanical device to
provide a hard stop to the product and therein precisely position the product
within the
workstation. A powered shuttle like transport 27 using several opposing sets
of rollers on at
Zo least two interlocking tracks 25 is moved over a precise path 39 by power
source 26. Integral
to the transport 27 is an assembly of one or more sets of at least two
telescoping sleeves 28 in
combination and coaxial arrangement. The outer sleeve being generally fixed to
the transport
27 and the inner sleeve 28 being allowed to move up and down along path 38.
Further, that a
combination of bushings and/or bearing devices 34 are used to maintain precise
alignment
is between outer sleeve and inner sleeve during longitudinal travel of the
inner sleeve within the
outer sleeve. Raising and lowering of the inner sleeve, along path 38, may be
performed by a
combination of various types of motors and actuating devices suited for
precise movement and
control of the cover holder 29. To retrieve a new cover the inner sleeve is
raised up and the
cover holder 29 is pivoted up 90 degrees from its normal position by actuator
33. The
so transport 27 is moved, over path 39, to a stack of covers 31. The inner
sleeve is lowered to
allow the cover holder 29 to make contact with upper most cover. Vacuum is
applied to a
series of cup like devices for grasping the cover. The transport 27 then moves
towards the
product and the cover holder 29, while holding a cover, is lowered to its
normal position by
actuator 33. Height information of the product obtained by sensor 35 is used
by a controller to
35 precisely align the cover 31 with the product cover attachment surface. A
pressure roller 36
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first engages the product upper surFace so as to provide sufficient pressure
to serve to detect
the movement and location of the product has it enters and leaves the
workstation.
The arrangement of the visual inspection 15, cover installation 13 and banding
6
s workstation, along a common and shared conveyor 1 provide a logical order in
a sequence of
operations necessary in concluding the packaging of a product before it is
shipped to a
customer. No one operation can be omitted. It also possible to extend the
distance between
workstations, while using a common and shared conveyor, to accommodate for
available space
within a facility or for closer proximity to other workstations in the
manufacturing process of
io the product. It is also further possible to separate one or more
workstation from the common
and shared conveyor and employ some other form of conveyance device to move
the product
from workstation to workstation where distance prohibits close proximity of
workstations.
ro~~~ Referring to FIG. 2 is a cross-section illustration, as identified in
FIG. 1 by A, of the
i5 visual inspection workstation. The product 22 is entered into the field of
illumination provided
by lamps 20 and view of video cameras 21 by powered conveyor 24. At least one
sensor 23 is
used to detect the entry and exist of the product 22 into the workstation.
Sensing entry into
the workstation the sensor 23 initiates energizing lamps 20 and video cameras
21. As the
product moves through the workstation image information from both sides of the
product 22 is
Zo transmitted to a central processing unit where it is simultaneously stored
and identified by a
product article number, date and time. The image information is also presented
to the system
operator through a computer monitor for means of examining the product for
possible
damage. To enhance visual detection polarized light and the angle of
illumination are
controlled so as to reduce reflection and improve the definition of product
defects and damage.
is When greater definition and resolution is required for detecting product
defects several video
cameras 21 and illuminators 20 can be arranged to provide a 3-dimension image
using
computer software applications. Additional cameras may also be included to
examine the
front, rear and upper surtaces of the product. To meet a variety of inspection
requirements
peculiar to various types of products still imaging, line scan and motion
video imaging may be
3o combined in various arrangements. Ultraviolet and Infrared illumination in
combination with
respective types of imaging systems may also be employed for inspecting
special types of
products.
Referring to FIG. 3 is a cross-section illustration, as identified in FIG. 1
by B, of the
s5 cover applicator workstation. The cover applicator serves to attach
protective covers to the
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CA 02490461 2004-12-14
is to retrieve, grasp and apply a new protective cover to products having a
rectangular box-like
shape. It is further capable of folding over panel like flaps extending from
the primary cover
so as to place them generally parallel to adjacent surfaces of the box-like
product shape. Once
folded down the entire cover will be securely attached to the product by means
of stapling,
s gluing or Velcro fastening. Cover holding plate 44 (backside shown) attaches
to the cover
installer transport (FIG.1) and is comprised of actuators 42, 50, 53 and
vacuum operated cover
grippers 51. Plates 41, 47 and 54 are attached to holding plate 44 through
hinges 52, 48 and
49. Actuators 42, 50 and 53 serve to retract and hold plates 41,47 and 54 in
the open position
during the retrieval and transporting of a new protective cover to the product
surface. The
~o actual securing of the cover to the holding plate 44 is provided means of
several vacuum
operated grippers 51 precisely placed and secured to the cover plate 44. The
vacuum grippers
51 are feed-through devices that protrude on the reverse surface of the cover
holding plate 44.
Another configuration is a flat shallow rectangular shaped chamber, exhibiting
a large number
of precisely spaced holes on one surface only and when vacuum is applied serve
as the cover
i5 gripper. In this configuration the chamber is integrated into the
construction of the cover
holding plate 44. Also precisely placed on plates 41, 47 and 54 are several
powered staplers
40, 43 when stapling is a required means of cover attachment. Additional
provisions for
folding tabs, present in certain types of covers, are smaller plates 45 and 56
hinged 46 to
plates 47 and 54. These plates are also operated by actuators 55 to fold cover
tabs down and
zo may comprise a powered stapler 40 when this is the required method
attachment.
~oo.Zy Referring to FIG. 5 is a rear view of the cover holder. In this view
the actuators 65, 62
and 61 are in the extended position so as to place the plates 59, 60, 64 and
smaller plates 57
inwards and therein place the cover extended panels on the adjacent surfaces
of from the
z5 primary larger cover. Several powered staplers 66, 58 are now actuated as
one form of
attachment method. With completion of the cover attachment vacuum is then
removed from
vacuum gripper 63 and the cover holder is removed from compression with the
product
surface.
so ~00.3~ Referring to FIG. 6 is a cross-section illustration, as identified
in FIG. 1 by B, of another
cover applicator workstation designed for installing a different form of
cover. The cover
applicator also serves to attach preformed covers to the sides, ends and upper
surface of a
rectangular box like shaped product. There are many forms and configurations
of covers the
cover applicator is adapted to installing and attaching to products. A product
entering into the
35 cover applicator workstation is detected by sensor 84, which serves to
determine its length,
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CA 02490461 2004-12-14
in the cover feeder 78 is performed by means of a device 77, which places a
constant preload
pressure on the cover stack.
roo.~.~ Referring to FIG. 7A and B is an illustration showing a powered X-Y
table 92 capable of
supporting substantially greater than 10,000 pounds. The table 92 provides the
means for
rotating a product 85, by means of rotating table section 93 over fixed
position table 91.
Rotating product 86 provides a means for positioning each of four sides, in a
sequenced
operation, to a single cover installer. Where only two cover installers are
employed the table
92 provides the means for rotating the product 85 so as to present two of four
sides, in a
to sequenced operation, to two oppositely opposed cover installers. Position
control and indexing
of table section 90 is provided by means of actuators providing lifting and
rotation movement
of at least one cylinder 87. Precise indexing is provided by means of a
positive protruding
wedges located on table section 90 that engages a mating surfaces on table
section 88. Any
number of other multiple and different means of indexing may also be applied.
~ooa~ Referring to FIG. 8 is a cross-section illustration, as identified in
FIG. 1 by C, of the
product cover banding workstation. The workstation is comprised of an
automated banding
machine 94 and a computer generated tag printer and applicator 95. As a
product 96 enters
the workstation sensor 97 detects its presence and initiates a signal to the
system controller.
Zo The controller retrieves the information on the product and initiates the
printing of an
identification code for the product, which has been visually inspected,
covered and now
banded.
coo.6~ Referring to FIG. 9 are several top, front and side views of a device
for installing
protective covers onto products surfaces through such means as to allow
simultaneously
folding extending cover panels onto product surf aces without the need of
powered
manipulating devices. Included also is a view of a typical protective cover. A
new protective
cover 116 is retrieved and held by vacuum present from several holes located
on the surface of
vacuum plate 112 which is attached to plate 111. Plate 111 is also attached to
at least two
so guides 110 which originate from a powered motor or actuator and which serve
to move and
place plate 111 and cover 116 to make contact with the product surface. A box
like cage 107
also shares guides 110, guides 108 and bearings 109, so as to operate in
arrangement and in
combination with plate 111. When the protective cover 116 is placed against
the product
surface by vacuum plate 112 and plate 111, forward motion of the cage 107
towards the plate
111 is initiated. The cage 107 walls leading inner edges are aligned so as to
make contact with
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the outside perimeter of one or more marking or creases present on the
protective cover to be
installed. Forward motion for cage 107 is provided by a powered motor or
actuator. Cage 107
travels along a controlled path, provided by guides 110 and as the cage 107
walls engage
cover 116 top panel 115 and side panels 113 they are forced beneath the cage
walls. The
s continuing forward motion of the cage 107 places the cover panels parallel
to the three
surfaces of the product. When the cage 107 stops an attachment means is then
initiated to
secure all sections of the cover to the product's three surfaces. Some
protective covers
produced employ additional small tab 114 like folding panels, which are placed
either below or
above the cover's top 115 folding panel. Two methods for folding these
additional panel tabs
io 114 are described. These methods are integrated into the upper wall of the
cage 107. A top
section view of cage 107 upper wall 99 is shown with a protruding tab 101 and
front view of
cage 107 with protruding tab 105. As the upperwall of cage 107 engages the top
panel 115 of
the cover 116 the protruding tab 101 and 105 start engaging the small tab 114
located on side
panel 113 of the cover. The protruding tab 101, 105 serves to start pushing
the small tab 114
i5 on the cover side panel 113 down onto the top panel 115. As the cage 107
travels further in
towards the cover 116 the sidewall 106 now starts folding the cover side panel
113 inwards.
The continuing forward travel of the cage 107 allows upper wall 99 to first
complete folding top
panel 115 down as the protruding tab 101, 105 progressively fold the cover's
side panel 113
small tab 114 inward and down against cover top panel 115. Cage 107 side walls
106 also
Zo simultaneously folds the cover side panel down. The same process takes
place when the small
tab 114 on the cover side panel 113 is to be placed beneath the cover's top
panel 115. In this
operation the cage 107 sidewall 104 is first to engage the cover's side panel.
As wall 104
progresses forward lip 102, 103 starts to fold the side panel tab down. When
the cage 107
upper wall 98 engages the cover's top panel and moves forward the cover's side
panel small
is tab 114 is now nearly compressed down so as to allow the cover's top panel
115 to rest above
the small tab 114. Several means are now possible for attaching the protective
cover to the
product's surface or to members of a crate containing the product.
Referring to 10 is a block diagram showing the various components and controls
so employed for the operation of this invention. Product leading and training
edge sensors 117 is
employed to detect the entry and egress of a product into a workstation. They
provide such
information necessary to control the actuation of other devices, the speed and
stopping of the
product through the workstation. Product height sensors 118 serve to measure
the height of
the product above the conveyor plane of reference. This information serves to
provide
s5 information to the controller, which may adjust the position of other
devices intended to
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contact and engage the product. The X-Y positioning sensors 119 provide
information as to
the actual location of the table and product relative to the cover installer.
The information will
confirm that the product is properly aligned or that there may be a fault
present in the
alignment. In such a condition the cover installer is inhibited from its
operating mode.
s Conveyor speed sensors 120 serve to provide accurate information on the
pertormance the
material handling system. Safety and Alarm sensors 121 serve to detect
failures in device and
system operation, which may be hazardous to continued system operation or
operating
personnel. Protective cover applicator X-Y position sensors 122 are those
sensors employed to
detect and measure the precise location of cover installer relative the
product to be covered.
io They operate within a closed-loop feedback system to provide information
for proportional
control of servos, actuators and motors necessary for precise engagement of
the cover to the
product surface geometry. Conveyor stop sensors 123 serve to initiate power
shut down in
event of component or system failure. End of line sensor 124 serve to alert
that a product has
completed the process and is now ready for removal. The product inspection
camera stations
15 128 serve to illuminate by means of camera station lighting 127 and take
high-resolution
real-time video images of all designated surfaces of the product through
cameras 129 before it
is covered. The visual images are presented to the system operator on a
monitor 132 for
remote viewing and examination of the product condition. The image information
is also
transmitted to a computer 130 where the image file is compressed into an
acceptable format
Zo and then placed into CD-ROM archiving. Manual control and operation of the
system is
provided through control panel 125. The operator has the option of manually
controlling each
interdependent operation performed in each of three workstations. The operator
also has the
option of selectively and fully automating workstations through controller
126. This allows the
means for dealing with varying product configurations entering the system.
This is also an
z5 important feature and capability when the system employs five cover
installing assemblies and
product configurations vary. In a fully automated operation of the system a
central controller
126 uses the data provided by all sensors and operator requirements to manage
and operate
the inspection workstation components 128, Cover applicator workstation 133
and Banding
workstation 135. When a product has been fully processed, information stored
in the central
3o controller on that product is transmitted to inspection tag printer 131
where a tag or label is
produced. The printed tag or label is then attached to the product by means of
an automated
inspection tag applicator 134. Monitor 132 is primarily used by the system
operator to
remotely view the surtaces of the product for the presence of damage. Multiple
real time
digital imaging devices such as still cameras, line scan and continuous motion
video cameras
35 are used in various arrangements in order to inspect a wide variety of
surfaces, which are
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CA 02490461 2004-12-14
possible in products. The inspection images are presented on the monitor 132
in an operator
controlled sequence or possibly on several monitors, one for each surface
under inspection. In
a more advanced version an arrangement of computer software, sensors and
imaging devices
can be programmed and used to detect damaged surfaces and initiate alarms and
system
controls to halt the process and alert the aperator.
A third embodiment of an applicatar apparatus for applying a protective cover
to a
product is shown in FIGS. 11-18. Referring to FIG. 11, the applicator
apparatus 200 includes a
magazine 210 which holds a stack of protective covers 212. The magazine
includes a base 214
io which pushes a pallet 216 in an upward direction so as to maintain the
upper level of the
magazine at a constant height. A frame 218 includes an alignment fixture 220
which maintains
the stack 212 in the proper orientation.
On the other side of the applicator apparatus 200, a stack of product 222 is
supported
i5 on a platform 224. In accordance with the system of FIG. 1, the stack of
material may be
moved by a carriage 226 along a pair of tracks 228a and 228b.
oom Between the magazine 210 and product conveyor a frame 230 supports a cover
manipulator 232. The cover manipulator 232 may be moved linearly along the
frame 230 from
zo a position adjacent the magazine 210 to a position adjacent the product
stack 222 by a
transport mechanism 234. The transport mechanism includes a chain or belt 236
which is
driven by a motor 238 which, in turn, causes a trolley 240 to which the cover
manipulator 232
is attached to move along tracks in the top of the frame 230. The trolley 240
has bearings
241a, 241b, that move on tracks 243a and 2 43b.
The cover manipulator 232 includes a structure comprising three arms or slats
242a,
242b and 242c which are coupled to a horizontal beam 244 which rests in
bearings 246a and
246b. Each of the three slats 242a, 242b and 242c have three vacuum-coupled
suction cups
248. The structure comprising the three slats 242a, 242b and 242c rotates on
the beam 244
so about its horizontal axis through an angle of 270 degrees as will be
explained below under the
control of a motor. The height of the cover manipulator 232, which includes
the entire
structure supported by the trolley 240, is controlled by pneumatic pistons
250a and 250b.
Thus, different sizes and configurations of product stacks 222 may be
accommodated. In
addition to the cover manipulator 232, the tralley 240 also supports a moving
cage 252 having
s5 opposite side arms 252a and 252b. Each of the arms 252a and 252b include
guides with
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CA 02490461 2004-12-14
rollers 254a and 254b. There are three of such guides and rollers in vertical
alignment on arm
252b and three guides and rollers on arm 252a. There are also four overhead
guides and
rollers 256 which are also mounted on the cage 252.
coos~~ Associated with each of the guidesjrollers 254a, 254b and overhead
guides/rollers 256
are fastening devices 258 which may be staple guns, riveters, nail guns and
the like. The use
of the particular form of the fastening device may be left up to the user, it
being recognized
that many such fastening schemes and mechanisms may be used with the
apparatus.
io ~oo5a~ Referring to FIG. 13, the magazine 210 includes a plurality of
protective covers 212
resting upon a moveable pallet mechanism 216. The covers are positioned by the
pallet
mechanism 216 until they are in proper position and alignment to be grasped by
the cover
manipulator 232. The covers must be kept at a predetermined height in order
for proper
operation and the height is automatically maintained by a scissor mechanism
262 operated by
i5 a pneumatic piston and cylinder 264. This insures that the top cover of the
stack 212 lies in a
plane parallel to the plane formed by the suction cups 248 of the cover
manipulator 232. The
structure formed by the three slats 242a, 242b, 242c along with the vacuum
suction cups 248
comprises a cover gripper which is rotatable between a position atop the stack
of protective
covers (refer to FIG. 14) through a 270 degree arc to a position flush against
the side or end of
Zo the product 222 (refer to FIG. 15). The product stack, which may be any
type of product but
is generally one which is in a box-like configuration and which may consist of
a stack of
substantially flat material such as sheets of plywood, fiberboard or other
composite materials,
is conveyed along the tracks 228a, 228b to a position adjacent the cover
applicator apparatus.
Its leading edge is held in place by stops 266a and 266b which are under the
control of
z5 pneumatic actuator 268. A turntable mechanism 270 pushes upwardly to lift
the product stack
222 and rotate it 180 degrees (refer to FIG.. 18). The particular form of the
turntable
mechanism is unimportant and may be pneumatic or may be operated by a screw
jack and
worm gear or the like. When rotation is completed, the turntable adjusts its
height so that the
top of the product stack 222 bears against a stop member 272 which sends a
signal to the
3o control system that the stack is at the proper height and stops the
vertical movement of the
turntable 270.
In operation, the cover manipulator 232 grasps a sheet of protective cover
material
212a from the magazine 212 by means of the suction cups 248. The cover
manipulator
35 structure 232 is then rotated 270 degrees around the horizontal beam 242
until it aligns with
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CA 02490461 2004-12-14
the vertical plane of the stack of material 222. Referring to FIG. 15, the
motor 238 then
causes the trolley 240 supporting both the cover manipulator 232 and the cage
252 to move
forward from a position adjacent the magazine 212 to a position at which the
protective cover
sheet 232a bears against a vertical side of the product 222. Sensors determine
when the cover
is properly placed against the stack of material 222. Referring to FIG. 16,
once this position is
reached the cage 252 moves forward folding the protective cover over the
corners and portions
of the sides and tops of the product stack 222. This is accomplished under the
action of the
guide/rollers 254a, 254b and 256. Once the rollers have flattened the top and
sides of the
protective cover 212a against the stack of material 222, the fasteners 258 are
activated which
to drive staples or the like through the protective cover 232a and fasten it
to the material stack
222. As shown in FIG. 18, the cage 252 i s withdrawn along with the cover
manipulator 232
back to a position adjacent the magazine. The height sensor 272 is withdrawn
and the
turntable raises the product stack 222 and rotates it 180 degrees in the
direction of the arrow.
The aforementioned process is then repeated for the opposite side of the
product 222.
ro~ss~ In addition to the structures and embodiments disclosed herein,
additional
modifications and substitutions for various components of the preferred
embodiments may be
made without departing from the spirit of the invention. For example, the
ot~ientation of the
magazines holding the protective covers and that of the cover manipulator may
be different
Zo depending upon the particular application desired. Instead of lying flat on
a pallet as shown in
FIG. 13, the protective covers could be arranged endwise vertically. That is
the covers could
be supported in a magazine on their bottom edges parallel to a vertical plane.
In such a case
the cover manipulator could be rotated 90" so that the structure supporting
the cover grippers
rotated about a vertical axis instead of a horizontal axis as shown in FIG.
12. Additionally the
structure itself could consist of any convenient configuration and, for
example, may be a single
robotic arm. Additionally the cover gripping mechanism is not limited to the
use of suction
cups or other vacuum-type devices. In the example given, a robodc arm could
have a gripper
that included scissor-like friction grippers in the nature of fingers which
could grasp each cover
from the magazine and hold it for transport over to the product to which it is
to be applied.
The terms and expressions which have been employed in the foregoing
specification
are used therein as terms of description and not of limitation, and there is
no intention, in the
use of such terms and expressions, of excluding equivalents of the features
shown and
described or portions thereof, it being recognized that the scope of the
invention is defined and
s5 limited only by the claims which follow.
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