Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
LOADING CASES WITH ITEMS
TECHNICAL FIELD
[0001] The present disclosure relates, generally, to packaging and, in
particular
embodiments, to loading cases with items.
BACKGROUND
[0002] Containers are used to package many different kinds of items. One
form of
container used in the packaging industry is what is known generically as a
"box" and it can
be used to hold various "items." Items may be defined to include individual
products and to
include other boxes containing products. Some in the packaging industry refer
to boxes used
to package one or more products as "cartons." Also, there are containers/boxes
that are
known, by some, as "cases." Examples of cases include what are known as
regular slotted
cases ("RSC"). In present application, including in the claims, the words
"cases," "cartons"
and "containers" are used collectively and interchangeably to refer to boxes,
cartons and/or
cases that can be used to package items.
[0003] Cases come in many different configurations and are made from a
wide variety of
materials. However, many cases are foldable and are formed from a flattened
state ¨
commonly called a "case blank." Cases may be made from an assortment of
foldable
materials, including, but not limited to, cardboard, chipboard, paperboard,
corrugated
fibreboard, other types of corrugated materials, plastic materials, composite
materials and the
like and, possibly, even combinations thereof.
[0004] In many known systems, case blanks may be serially retrieved, from
a magazine,
reconfigured, from a flattened state into an erected state, and then placed in
a slot on a
conveyor. The case blank in the erected state may be moved by the conveyor to
a loading
station where the case blank in the erected state may be filled with one or
more items and
then sealed.
[0005] To permit the case blanks to be readily opened up into the erected
state from the
flattened state, the case blanks may be held in the magazine in a generally
completely
flattened configuration. The case blanks may then be folded and sealed, such
as by gluing or
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Date Regue/Date Received 2022-12-30
taping panels and/or flaps together, to form an erected case blank.
Specialized apparatus that
can handle only flat, unfolded and unsealed case blanks are known.
[0006] Some case blanks are provided to users not in a flat, unfolded and
unsealed form
but, rather, in a form that is known as a "knock-down" blank or "KD blank." A
KD blank
may be provided in a folded and flattened configuration and may be partially
glued or
otherwise partially sealed, such as along one side seam, thus being formed in
a generally
flattened tubular shape. Accordingly, each case blank may require opposite
panels to be
pulled apart and reconfigured from a flattened tubular configuration to an
erected, open
tubular or sleeve-like configuration that is suitable for delivery to another
system such as a
conveyor. The case blank may then have one side opening closed by folding and
sealing the
flaps and may then be filled from the opposite side with one or more items
while on the
conveyor (this scheme may be referred to as "side loading"). Also, any
required additional
flap folding and sealing, such as with glue or tape, can be carried out to
enclose and
completely close and seal the loaded case blank with the one or more items
contained therein.
Alternately, for example, an erected case blank can be reoriented from a side
orientation to an
upright orientation with the opening facing upwards and a having a sealed
bottom end. The
erected case blank can then be moved to a loading system where it may be
filled from its top
side with one or more items via an opening that is facing upwards (this scheme
may be
referred to as "top loading"). The one or more items may be top loaded using,
at least in part,
gravity to "drop" the one or more items into the erected, bottom sealed case
blank. The top
opening of the case blank can then be closed by folding over and sealing the
top flaps.
[0007] However, in some situations, it is not desirable to top load or
side load items into
an erected carton/case. For example, top loading and side loading may be
considered
undesirable in situations wherein the size and shape of items to be loaded are
narrow or
tapered on the top and sides. This can present a challenge for the automated
loading of items.
For example, an electromechanical system may have challenges to lift and
adjust a group of
several items as a result of the shape of the items. Also, top loading items
into a tightly fitting
interior space area of an open top case blank can be challenging. Furthermore,
some items,
such as glass or plastic bottles, are particularly susceptible to being
damaged or broken when
being top loaded into an erected carton/case, particularly when they are "drop
packed" into an
erected case blank.
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Date Recue/Date Received 2022-12-30
SUMMARY
[0008] A system is disclosed for loading cases with items. An item
delivery apparatus
delivers a plurality of items to a location for collating the items on a
collation platform. A
transfer apparatus transfers a plurality of items from the collation platform
to a pedestal,
where the plurality of items are surrounded, on three sides, by a fence. A
case movement
apparatus, such as a cartesian robot moves an erected case blank in a path
that sheaths, with
the erected case blank, a group of items located on the pedestal. As the case
blank is dropped
vertically downward to sheath the group of items, the fence is moved
vertically downward
and out of the way of further processing of the, now loaded, case blank.
[0009] According to an aspect of the present disclosure, there is
provided a system for
loading cases with items. The system includes an item delivery apparatus
operable to deliver
a plurality of items to a transfer station, a collation platform operable to
support a group of
items, a pedestal operable to support the group of items and a transfer
apparatus. The transfer
apparatus is operable to transfer a plurality of items from the item delivery
apparatus at the
transfer station, to the collation platform, to form the group of items on the
collation platform
and transfer the group of items from the collation platform to the pedestal.
The system further
includes a fence and a fence support apparatus, wherein the fence is arranged
to surround, on
three sides, the group of items on the pedestal and a case movement apparatus
located
proximate the pedestal apparatus, the case movement apparatus operable to move
an erected
case blank in a path that sheaths, with an erected case blank, a group of
items located on the
pedestal. In operation, the item delivery apparatus delivers a plurality of
items to the transfer
station, the transfer apparatus transfers a plurality of items from the item
delivery apparatus at
the transfer station, to the collation platform, to form a group of items on
the collation
platform, the transfer apparatus transfers the group of items from the
collation platform to the
pedestal, the case movement apparatus moves the erected case blank to sheath
the group of
items located on the pedestal and the fence support apparatus moves the fence
vertically
downward while the case movement apparatus moves the erected case blank to
sheath the
group of items.
[0010] Other aspects and features will become apparent to those of
ordinary skill in the
art upon review of the following description of specific embodiments of the
invention in
conjunction with the accompanying figures.
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Date Recue/Date Received 2022-12-30
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a more complete understanding of the present embodiments, and
the
advantages thereof, reference is now made, by way of example, to the following
descriptions
taken in conjunction with the accompanying drawings, in which:
[0012] FIG. 1 illustrates, in a front-right-upper perspective view, a
system for loading
erected case blanks with one or more items and closing and sealing the top and
bottom ends
of loaded case blanks, in accordance with aspects of the present application;
[0013] FIG. 2 illustrates, in a block diagram, computer components used
to manage the
system of FIG. 1, in accordance with aspects of the present application;
[0014] FIG. 3A illustrates, in a top view, an example non-erected case
blank that can be
used in the system of FIG. 1, in accordance with aspects of the present
application;
[0015] FIG. 3B illustrates, in a perspective view, the example non-
erected case blank of
FIG. 3A;
[0016] FIG. 3C illustrates, in a perspective view, the example non-
erected case blank of
FIG. 3A, in an erected configuration;
[0017] FIG. 4 illustrates, in a back-left-upper perspective view, the
system of FIG. 1, in a
phase of operation;
[0018] FIG. 5 illustrates, in a back-left-upper perspective view, the
system of FIG. 1, in a
phase of operation subsequent to the phase illustrated in FIG. 4;
[0019] FIG. 6 illustrates, in a back-left-upper perspective view, the
system of FIG. 1, in a
phase of operation subsequent to the phase illustrated in FIG. 5;
[0020] FIG. 7 illustrates, in a back-left-upper perspective view, the
system of FIG. 1, in a
phase of operation subsequent to the phase illustrated in FIG. 6;
[0021] FIG. 8 illustrates, in a back-right-upper perspective view, the
system of FIG. 1, in
a phase of operation similar to the phase illustrated in FIG. 7;
[0022] FIG. 9 illustrates, in a back-right-upper perspective view, the
system of FIG. 1, in
a phase of operation subsequent to the phase illustrated in FIG. 8;
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Date Regue/Date Received 2022-12-30
[0023] FIG. 10 illustrates, in a back-right-upper perspective view, the
system of FIG. 1,
in a phase of operation subsequent to the phase illustrated in FIG. 9;
[0024] FIG. 11 illustrates, in a back-right-upper perspective view, the
system of FIG. 1,
in a phase of operation subsequent to the phase illustrated in FIG. 10;
[0025] FIG. 12A illustrates, in a front-plan view, a subset of components
of the system
of FIG. 1, including an erected case blank, a fence and a pedestal supporting
a plurality of
items, wherein the erected case blank is held above the plurality of items;
[0026] FIG. 12B illustrates, in a front-plan view, the subset of
components illustrated in
FIG. 12A, wherein the erected case blank is has been moved to partially sheath
the plurality
of items;
[0027] FIG. 12C illustrates, in a front-plan view, the subset of
components illustrated in
FIG. 12A, wherein the erected case blank is has been moved to fully sheath the
plurality of
items;
[0028] FIG. 13 illustrates, in a schematic perspective view, a subset of
components of the
system of FIG. 1, including an erected case blank, a pedestal, first folding
platform and a
second folding platform, the subset being shown in various positions of a
loaded case blank
during movement across the pedestal, the first folding platform and the second
folding
platform, in accordance with aspects of the present application; and
[0029] FIG. 14 illustrates, in a flow chart diagram, example steps in a
method of filling a
case blank with items and closing and sealing the top and bottom ends of the
case blank.
DETAILED DESCRIPTION
[0030] For illustrative purposes, specific example embodiments will now
be explained in
greater detail in conjunction with the figures.
[0031] The embodiments set forth herein represent information sufficient
to practice the
claimed subject matter and illustrate ways of practicing such subject matter.
Upon reading the
following description in light of the accompanying figures, those of skill in
the art will
understand the concepts of the claimed subject matter and will recognize
applications of these
Date Regue/Date Received 2022-12-30
concepts not particularly addressed herein. It should be understood that these
concepts and
applications fall within the scope of the disclosure and the accompanying
claims.
[0032] Moreover, it will be appreciated that any module, component, or
device disclosed
herein that executes instructions may include, or otherwise have access to, a
non-transitory
computer/processor readable storage medium or media for storage of
information, such as
computer/processor readable instructions, data structures, program modules
and/or other data.
A non-exhaustive list of examples of non-transitory computer/processor
readable storage
media includes magnetic cassettes, magnetic tape, magnetic disk storage or
other magnetic
storage devices, optical disks such as compact disc read-only memory (CD-ROM),
digital
video discs or digital versatile discs (i.e., DVDs), Blu-ray DiscTM, or other
optical storage,
volatile and non-volatile, removable and non-removable media implemented in
any method
or technology, random-access memory (RAM), read-only memory (ROM),
electrically
erasable programmable read-only memory (EEPROM), flash memory or other memory
technology. Any such non-transitory computer/processor storage media may be
part of a
device or accessible or connectable thereto. Computer/processor
readable/executable
instructions to implement an application or module described herein may be
stored or
otherwise held by such non-transitory computer/processor readable storage
media.
[0033] In some packaging situations, it may be desirable to be able
"bottom load" a
carton/case. In a bottom loading operation, there is relative upward movement
of one or more
items through a case opening that is oriented/facing in a downward direction.
However, there
are significant challenges in bottom loading of case, such as, for example,
the difficulty of
closing the bottom flaps when items are otherwise supported within the
interior storage space
of an erected carton/case.
[0034] With reference to FIG. 1, in overview, a system 100 operable for
loading a
plurality of items 102 (referenced collectively or individually by reference
numeral 102) into
cases formed from selected ones of a plurality of case blanks is illustrated.
Individual items
among the plurality of items 102 may be singular units of a manufactured
product, which
may be delivered to the system 100 from a separate manufacturing facility or
from another
source. The items 102 may feature a rigid body, which rigid body may have an
interior cavity
that may hold a substance. For example, the individual items 102 may be
individual glass or
plastic bottles containing a liquid such as a beverage (e.g., bottles of wine
or beer) or
individual bottles or other rigid containers holding another material or
substance, such as a
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Date Recue/Date Received 2022-12-30
liquid, for example, laundry detergent. The items 102 may alternatively be
paperboard or
composite cartons (such as cartons of juice or milk) or metal, paperboard or
composite cans
of a product such as cans of a food or cans of spray paint. Each item 102 may
be a rigid (or
semi-rigid) item and may be an item for which there exists a desire to collate
and/or bottom-
load into an interior storage space 107 defined by interior surfaces of panels
A-D of an
erected case blank 111C (see FIG. 3C). Typically, each item 102 loaded into
the erected case
blank 111C using the system 100 will be stable and self-supporting, at least
when formed into
a collated group 122 (see FIG. 4) of items. Each item 102 may be self-
supporting on a base
portion. The plurality of items 102 may not be a type of container containing
a substance but,
rather, some other self-supporting rigid, or semi-rigid, item to be loaded
into a case. In
aspects of the present application, the items 102 may be self-supporting and
stable only when
formed into the collated group 122 of items.
[0035] Each item 102 among the plurality of items 102 may be configured
with a base
portion configured to support the item 102 in a generally vertically upright
orientation. One
example of such a base portion is a generally flat base support surface. Each
item 102 may be
shaped with a main lower body portion having an outer surface of a first cross-
sectional
size/diameter and an upper neck region having an outer surface of a smaller
cross-sectional
size/diameter; note that the shape of a typical wine bottle fits this
description. By way of
example only, each item 102 may be a 150 ml plastic or glass bottle with an
upper cylindrical
shorter neck region, a vertically extended generally cylindrical body portion
and a bottle cap
or other closure secured over a top opening in the neck region. The interior
cavity of each
item 102 may be occupied by a liquid, or a semi-liquid, product. Each item 102
may have a
shoulder formed at the join between the body portion and the neck
portion/closure.
[0036] With reference to FIGS. 3A, 3B and 3C, each case blank 111A used
in the system
100 of FIG. 1 may have opposed minor side panels A and C interconnected to a
pair of
opposed major side panels B and D that, together, form a tubular sleeve,
illustrated in FIG.
3C, when the flat case blank 111A has been opened. An overlap strip of case
blank material
may be provided between panel B and panel A. The overlap strip may be sealed,
by
conventional means, such as a suitable adhesive, to provide an overlapping
seam joint in the
vicinity of "P" (see FIG 3A). This seam joint forms a knock-down case blank in
which the
panels A, B, C and D are joined into the flat case blank 111A that is of
generally flattened
tubular configuration, as shown in FIGS. 3A and 3B.
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Date Recue/Date Received 2022-12-30
[0037] Also, as shown in FIGS. 3A, 3B and 3C, the flat case blank 111A
includes
opposed pairs of end flaps E, H, L, I that are positioned at one end (e.g.,
the top end) of the
respective side panels A, B, C, D. A second set of opposed pairs of end flaps
F, G, K, J are
positioned at the opposite end (e.g., the bottom end) of side panels A, B, C,
D. However, in
other aspects of the present application, case blanks having other panel and
flap
configurations are contemplated. The panels and flaps may be connected to
adjacent
flaps/panels by predetermined fold/crease lines, such as the fold/crease lines
illustrated in
FIGS. 3A and 3B. These fold/crease lines may, for one example, be formed by a
weakened
area of material and/or may, for another example, be formed using a crease
forming
apparatus. The effect of the fold/crease lines is that one panel, such as, for
example, panel A,
can be rotated relative to an adjacent panel such as, panel D or panel B,
along the fold/crease
lines. Flaps may also fold and rotate about fold/crease lines that connect the
flaps to their
respective panels.
[0038] The flat case blanks 111A may be made of any suitable material(s)
configured
and adapted to permit the required folding/bending/displacement of the
material to reach the
desired configuration. Examples of suitable materials are chipboard, cardboard
or creased
corrugated fiberboard. It should be noted that each flat case blank 111A may
be formed of a
material that, itself, is rigid or semi-rigid and not easily foldable but that
is divided into
separate panels and flaps separated by creases or hinge-type mechanisms, so
that the flat case
blank 111A can be erected and formed. In some aspects of the present
application, the flat
case blanks may be delivered to the system 100 of FIG. 1 in a form in which
the case blank is
already in a tubular shape and may be completely or partially sealed at an
upper end, with the
bottom end being open. In some aspects of the present application, each case
blank may not
be rectangular or square in horizontal section shape.
[0039] The system 100 of FIG. 1 may have a programmable logic controller
("PLC")
132 (see FIG. 2) for controlling various operational components of the system.
The system
100 may also include a first cartesian robot 250-1, a second cartesian robot
250-2, a blank
magazine 251 and an item infeed conveyor 104. The blank magazine 251 may be
configured
to hold a plurality of vertically stacked, flat case blanks 111A.
[0040] In operation, a header 116 may be operable to successively
transfer a plurality of
items from the infeed conveyor 104 to a collation platform to, thereby, form a
collated group
122 of items. The system 100 may also include an area where the collated group
122 of the
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Date Regue/Date Received 2022-12-30
plurality of items 102 may be loaded into the erected case blank 111C (see
FIG. 3C), thereby
producing a loaded case. Subsequently, the system 100 may act on the loaded
case to close
the end flaps and seal the loaded case. The process of forming the collated
group 122, loading
the collated group 122 into its own respective erected case blank 111C and
sealing the case
may be repeated.
[0041] In some aspects of the present application, top end flaps of each
erected case
blank 111C may be closed and sealed, or partially sealed, prior to loading of
the groups 122
of items 102 therein. Within the casing area there may be located several
components,
including the first cartesian robot 250-1, the second cartesian robot 250-2, a
pedestal 140 and
a fence 124. The transfer apparatus may operate to successively move the
groups 122 of
collated items 102 from the collation platform to the pedestal 140.
[0042] The collation platform may receive the individual items 102, from
the infeed
conveyor 104, delivered singly and in series. The items 102 may be delivered
to a transfer
location as a single line of items, with no spacing between adjacent items 102
in the single
line. In other aspects of the present application, the items 102 may be
delivered with a
predefined spacing therebetween. In further aspects of the present
application, the items 102
may be delivered with randomly sized spacing between each of the items 102.
The system
100 may be operable to transform the plurality of individual items 102
provided to system
100 into a series of collated groups 122 of items 102, so that each collated
groups 122 may be
delivered serially to the casing area for loading and sealing in its own case.
[0043] The individual items 102 may be delivered by the input conveyor
104, in a series
and in a generally vertically upright orientation with each item 102 supported
on its base
portion, to a transfer station. The transfer station is a location at the end
area of the infeed
conveyor 104 and at the input area of the collation platform. The plurality of
items 102 that
form a sub-group of items may be transferred from the input conveyor 104 to
the collation
platform. Successive sub-groups/rows of the items 102 may be transferred from
the input
conveyor 104 to the collation platform to form the completed, collated group
122. Several
sub-groups/rows of items (each of which may form a single row in the group 122
comprising
multiple rows of items) may be aggregated/collated to form the group 122 of
the items 102.
Thus, between the input conveyor 104 and the collation platform, the
individual items 102
may be transformed from a series of individual items 102 delivered in series,
into the collated
group 122 on the collation platform.
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Date Recue/Date Received 2022-12-30
[0044] The collation platform may have an item support surface made of a
strong, low
friction material such as Ultra-High Molecular Weight (UHMW) polyethylene to,
thereby,
allow the items 102 to easily slide over the item support surface.
[0045] The group 122 may be formed on the collation platform in an
ordered array of the
items 102. For one example, the ordered array may be a rectangular array of a
first number,
Ni, of rows of the items 102 and a second number, N2, of the items 102 in each
row.
Depending upon the desired configuration of the array of the items 102 when
loaded into the
erected case blank 111C, adjacent rows of items may be transversely offset
from each other.
That is, if the items 102 are generally cylindrical, the items 102 may be
interleafed at their
outer abutting surface areas. The number of the items 102 in each group 122 to
be loaded into
a single erected case blank 111C may be determined based on one or more
specific
dimensions and shapes associated with the individual items 102, the shape of
the interior
storage space 107 in the erected case blank 111C and dimensions of the
interior storage space
107.
[0046] At least some, if not all, of the components of the system 100 of
FIG. 1 may be
mounted to a system frame 115. Notably, only some of the system frame 115 is
illustrated in
the Figures. The system frame 115 may include various inter-connected vertical
and
horizontal post/beam support members, such as frame members 115'. The system
frame 115
may be configured to permit certain components, that are described herein, of
the system 100
to be mounted thereto.
[0047] In further operation, the collated groups 122 of the items 102 may
be sequentially
transferred from the collation platform to the pedestal 140 in the casing
area, using a
combination of the transfer apparatus and the fence 124. At the casing area,
each collated
group 122 of items 102 may be sequentially bottom loaded into the interior
storage space 107
(FIG. 3C) of the erected case blank 111C by having the erected case blank 111C
moved by
the second cartesian robot 250-2, under control of the PLC 132, in a
particular and pre-
determined path such that the collated group 122 of items 102 is sheathed by
the erected case
blank 111C. The erected case blank 111C may be moved on a path whereby the
erected case
blank 111C is tilted at an angle and then brought down over top of the
collated group 122 of
items 102, so as to encapsulate or enclose the collated group 122 of items 102
within the
interior storage space 107 of the erected case blank 111C, while the collated
group 122 of
items 102 is positioned on the collation platform and while the collated group
122 remains
Date Recue/Date Received 2022-12-30
stationary relative to the system frame 115. The path of movement of the
erected case blank
111C, as the erected case blank 111C is moved by the second cartesian robot
250-2, may be
configured such that none of the lower flaps (e.g., flaps J, K, F, G) are
caught on any upper
edges or upper surfaces of any of the items 102 in the collated group 122 and
such that the
erected case blank 111C is moved to a position wherein the lower flaps (e.g.,
flaps J, K, F and
G) remain oriented vertically downwards when the collated group 122 of items
102 has been
received within the interior storage space 107 of the erected case blank 111C.
[0048] Once the collated group 122 of items 102 has been properly
positioned within the
interior storage space 107 of the erected case blank 111C, at least two
opposed bottom flaps
(e.g., the trailing flap G and the leading flap F) of each erected case blank
111C may be
moved to a closed position using a combination of the second cartesian robot
250-2, the
pedestal 140, a first folding platform 163 (see FIG. 11) and a second folding
platform 165
(see FIG. 10). Thereafter, the loaded case blank 111D, with at least the flaps
G and F having
been moved to a closed position, may be moved, by the second cartesian robot
250-2, from
the pedestal 140 to the output conveyor 170. During movement to the output
conveyor 170,
and/or while being moved on the output conveyor 170, the loaded case blank
111D may have
the remaining top and bottom flaps closed and the top and bottom ends may also
be fully
sealed. Optionally, the loaded case blank 111D may be labelled, using a
labelling apparatus,
while the loaded case blank 111D is moving through the output conveyor 107.
Thereafter, the
output conveyor 170 may deliver each loaded and fully sealed case blank 111E
to an output
station, where, for example, each loaded and fully sealed case blank 111E may
be
successively stacked on a pallet by a conventional stacking apparatus (not
shown) to be ready
for shipping to a destination.
[0049] An example of a scheme for the power and data/communication
configuration for
the system 100 of FIG. 1 is illustrated in FIG 2. The operation of the
components of the
system 100 may be controlled by the PLC 132. The PLC 132 may be accessed and
configured by a human operator through a Human Machine Interface (HMI) module
133
secured to the frame 115. The HMI module 133 may be in electronic
communication with the
PLC 132. The PLC 132 may be any suitable PLC and may, for example, include a
unit
chosen from the Logix 5000 series devices made by Allen-Bradley/Rockwell
Automation of
Milwaukee, Wisconsin, such as the ControlLogix 5561 device. The HMI module 133
may be
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Date Regue/Date Received 2022-12-30
a Panelview (part number 2711P-T15C4D1) module, also made by Allen-
Bradley/Rockwell
Automation.
[0050] Electrical power may be supplied to the PLC 132/HMI 133 and may be
supplied
to various servo motors and direct current (DC) motors that are described
further herein.
Compressed/pressurized air may also be supplied to vacuum generators and
pneumatic
actuators through valve devices, such as solenoid valves, that are controlled
by the PLC 132.
Servo motors may be connected to, and may be in communication with, servo
drives that are
in communication with, and controlled by, the PLC 132. Similarly, DC motors
may be
connected to DC motor drives that are in communication with, and controlled
by, the PLC
132, again all as described further herein. Additionally, various other
sensors are in expected
to be in communication with the PLC 132 and may (although not shown) also be
supplied
with electrical power.
[0051] With reference to FIGS. 3A, 3B and 3C, an example of one kind of
knock-down
case blank 111A that can be processed by system 100 to form a regular slotted
case (RSC) is
illustrated. The system 100 of FIG. 1 may be configured so that other types of
knock-down
case blanks and knock-down case blanks of different sizes may also be
processed.
[0052] Each case blank may be generally initially formed and provided in
a knock-down
configuration 111A ¨ i.e., a flattened tubular configuration ¨ as shown in
FIGS. 3A and 3B.
Each tubular case blank 111A may have a height dimension "Ht"; a length
dimension "L";
and a major panel length dimension "Q" (see FIG 3A). By inputting, into the
PLC 132, each
of these three dimensions for a case blank to be processed by the system 100,
the PLC 132
may determine whether the system 100 can process a case blank 111A of that
size without a
necessity for manual intervention to make an adjustment to one or more
components of the
system 100. If the PLC 132 determines that an adjustment can be made without
human
intervention, the PLC 132 may make the necessary adjustments to positions
and/or
movements of at least some of the components forming the system 100.
[0053] As will be described further hereinafter, the tubular case blank
111A may be
transformed from a knock-down configuration (i.e., a generally flattened
tubular
configuration) to an open-sleeve, erected configuration (open tubular
configuration, "the
erected case") associated with reference numeral 111C. The erected case blank
111C may be
loaded and the end flaps may be folded and sealed to form a desired erected,
loaded and fully
12
Date Regue/Date Received 2022-12-30
closed and sealed case configuration 111E (more succinctly called "the loaded
and fully
sealed case blank 111E"). The system 100 may be configured to deliver each
erected case
blank 111C with a downwardly facing, bottom opening with flaps F, G, J, K
being in an
orientation that is generally planar with corresponding connected side panels
A, C, B and D,
suitable for loading a group of items 102 through the bottom opening into the
interior storage
space 107 of the erected case blank 111C, where the group of items 102 are to
be held.
[0054] With reference now to FIG. 4, the infeed conveyor 104 may be a
driven conveyor
with a moving conveyor belt 104' that provides an upward facing, moving
support surface
that can support the plurality of items 102 thereon. The infeed conveyor 104
may be
configured to deliver the individual items 102 from a source/supply of such
items to a
transfer location at the transfer station 110, adjacent to, and generally
level with, the support
surface of the collation platform. The support surface of the conveyor belt
104' of the infeed
conveyor 104 may be configured as a movable continuous belt having an upper
run and lower
run with items supported on the upper run. The support surface of the conveyor
belt 104' of
the infeed conveyor 104 may made from a suitable material that will allow
items to easily
slide over the support surface of the conveyor belt 104' when pushed by the
header 116.
Example suitable materials include hard plastic materials that are commonly
used in belt
conveyors. The conveyor belt 104' may be driven by a conveyor belt motor 105,
such as a
DC motor or a variable frequency drive motor controlled by the PLC 132 through
a DC
motor drive. One example suitable DC motor drive is model AXH-5100-KC-30 from
the
Oriental Motor Co., Ltd. Of Japan. The upward facing surface of the conveyor
belt 104' may
have an end-run portion at a location that is adjacent to a forward transverse
edge region of
the support surface of the collation platform. In other aspects of the present
application, other
types of item delivery/supply apparatuses may be provided, including other
types of
conveyors, such as, by way of example only, magnetic conveyors or roller
conveyors.
[0055] The system 100 of FIG. 1 may also include the transfer apparatus
at the transfer
station oriented in a direction transverse to the direction of motion of the
items 102 on the
infeed conveyor 104. The transfer apparatus may have a pusher header 116 that
operates
across the end of the conveyor belt 104' of the infeed conveyor 104 and onto
the forward
edge region of the collation platform. The transfer apparatus may include an
actuator 114
attached to pusher header 116 that is capable of intermittent, linear,
reciprocating back and
forward movement under the control of the PLC 132. When activated by the PLC
132, the
13
Date Recue/Date Received 2022-12-30
actuator 114 may be configured to translate the header 116 between a first,
retracted position
and a second, extended position, in a direction that may be generally
perpendicular to the
direction of inflow of the items 102 on the conveyor belt 104' at the end
region of the infeed
conveyor 104. The reciprocating, linear movement of the header 116 may be
generated using
a piston, lead screw, or belted motor system. An example suitable motor is a
servo motor,
such as the model MPL-B330P-MJ24AA made by Allen-Bradley. The header 116 may
be
removably or permanently affixed to a support beam.
[0056] According to some aspects of the present application, the header
116 with a
particular shape/set of dimensions may be removed and interchanged with
another header 116
having an alternative shape/set of dimensions. It follows that, if the size
and/or shape of
individual items 102 require a specific design for the header 116, a header of
a desired
shape/dimensions may be selected and installed to correspond/fit the items 102
being
processed by the system 100 at a particular time. The header 116 may have a
generally flat
pushing surface that is vertically oriented and that also extends across the
body regions of the
plurality of individual items 102 located at the end region of the infeed
conveyor 104. In
some aspects of the present application, the header 116 may have a
complementary engaging
surface shape to that of the body region surface shape of the individual items
102 being
delivered by the infeed conveyor 104. For example, the header 116 may have a
plurality of
concave surface shapes arranged in series, which concave surface shapes
closely match the
convex outer surfaces shapes of the plurality of items 102 arranged in series,
when located at
the end region of the infeed conveyor 104.
[0057] As shown in FIG 4, in a first retracted position, the header 116
does not impede a
flow of the infeed conveyor 104 and is positioned outside of the conveyor path
of the
conveyor belt 104' in the end region. This lack of impedance allows an inflow
of several of
the individual items 102 into the end transfer region of the infeed conveyor
104. Therefore,
several of the individual items 102 that form the group 122 of items may be
positioned to
extend across the width of the operational surface of the header 116.
[0058] The system 100 of FIG. 1 may be configured to operate the infeed
conveyor 104
(with the items 102 delivered in a tight-contact, serial formation) and the
header 116 in a
manner that provides for the smooth sliding movement of each sub-group of
items 102 from
the infeed conveyor 104 onto the collation platform to form a row of items
102. For example,
based on a calculated timing of operation of the infeed conveyor 104, the PLC
132 may send
14
Date Recue/Date Received 2022-12-30
an input signal to intermittently start and stop movement of the infeed
conveyor 104 to
deliver the given number, N2, of items 102 to a transfer position.
Alternatively, one or more
electronic eye sensors, such as the model 42KL-D1LB-F4 eye sensors made by
Allen-
Bradley may be communicably linked to the PLC 132. A sensed value/signal may
indicate
that the number, N2, of specific individual items 102 that will form a row are
all located in
the desired specific positions at a transfer position. Responsive to receiving
the sensed
value/signal, the PLC 132 may signal to the infeed conveyor 104 to stop
movement of the
conveyor belt 104' of the infeed conveyor 104. The number of individual
products 102 that
are positioned on the infeed conveyor 104, spanning across the operational
surface of the
header 116 and forming a row of items 102, may correspond to the number, N2,
of items that
are desired for the collated row for each arrayed group 122 of products 102
that it is desired
to fit into the loaded and fully sealed case blank 111E, the loaded and fully
sealed case blank
111E containing the number, Ni, of the collated rows in the arrayed group.
[0059] The header 116 may be configured and operable to move from the
first, retracted
position to a second, extended position in a plough-like movement, to
transversely push and
slide the number, N2, of individual items 102 in the sub-group at the transfer
location from
the infeed conveyor 104 onto an upper item support surface of the collation
platform.
[0060] Responsive to the PLC 132 determining that the collated row is
present at the
transfer position spanning across the surface of the header 116, the PLC 132
may send a
signal to the actuator 114 to activate and, thereby, initiate movement of, the
header 116. In
operation, the header 116 carries out movement from the first position to the
second position.
Through this movement, the header 116 will push against the individual items
102 to,
thereby, push the individual items 102 from the infeed conveyor 104 onto the
collation
platform. This movement may be accomplished in a manner that causes the
individual items
102 to slide smoothly and together on their bases from the infeed conveyor 104
onto the
upper surface of the collation platform. The movement of the header 116 may be
carried out
at a predefined speed. Accordingly, the movement of the collated row of the
items 102 may
be of a character that the individual items 102 will be less likely to topple
over than the
individual items 102 would be if the movement was carried out at a speed
higher than the
predefined speed. This movement is expected to result in a first collated row
on the collation
platform.
Date Recue/Date Received 2022-12-30
[0061] After moving from the first position to the second position, the
header 116 will be
returned back to the first position (i.e., the position occupied by the header
116 as illustrated
in FIG. 4) under control of the PLC 132. Once the header 116 has been returned
to the first,
retracted position, a new subgroup of individual items 102 may be delivered to
the end region
of the infeed conveyor 104 and the transfer location, under control of the PLC
132. This
subgroup may then also be pushed by the header 116 onto the collation
platform, also causing
any prior sub-groups/rows of items 102 that are already on the collation
platform, to move
longitudinally, further downstream on the support surface of the collation
platform. This
process may be repeated until the desired number, Ni, of subgroups of items
102, arranged in
collated rows, are on the collation platform to form a desired size of the
group 122 of collated
items 102 to be loaded into the erected case blank 111C.
[0062] The item support surface of the collation platform may be a low
friction material
to, thereby, allow for easy sliding of the items 102 supported on their bases,
across the
adjacent and vertically and transversely aligned upward facing support
surfaces. Side plates
may be also provided in association with the collation platform. The side
plates may extend
on both transverse sides of the length of the collation platform to, thereby,
form bumper
members (bumpers) with inward facing support surfaces at a fixed
width/transverse spacing
corresponding to the width of the collated row. The bumpers may be constructed
with metal
support frames and may have inner support surfaces of a similar low friction,
high rigidity
material such as UHMW polyethylene, to allow each of the collated rows to
maintain its
positioning and to restrict sliding movement to a single dimension (e.g., easy
sliding along
the collation platform).
[0063] According to some aspects of the present application, the distance
between the
bumpers may be adjustable, such that the bumpers may be repositioned to
operate with the
header 116 when the header 116 has different width dimensions, to allow for
different
dimensions of the collated items 102 and/or different numbers of items in each
of the collated
rows of the desired group 122. For automatic adjustment by the PLC 132, the
bumpers could
be mounted on an adjustment mechanism that provides for spacing adjustments
through
operation of a servo motor, in a manner similar to the manner described
elsewhere herein.
[0064] Responsive to determining that the desired group 122 has been
collated upon the
collation platform, the header 116 may be activated to transfer the group 122
of collated
items 102 from the collation platform to the pedestal 140. The fence 124
surrounds the group
16
Date Recue/Date Received 2022-12-30
122 of collated items 102 on three sides, thereby providing support and acting
to prevent
tipping of the items 102.
[0065] Once transferred to the pedestal apparatus 140, each group 122 of
items 102 may
then be sheathed/covered with the erected case blank 111C under control of the
second
cartesian robot 250-2.
[0066] The pedestal 140 may be located among generally horizontal support
surfaces
upon which the collated group 122 of items 102 may be moved over and supported
while
being sheathed by/enclosed within the erected case blank 111C under control of
the second
cartesian robot 250-2. The horizontal support surfaces associated with the
pedestal 140 may
be made from a suitably strong, low friction material, such as a low friction
stainless steel.
Transfer from the collation platform to the pedestal 140 may be performed
using the header
116 to move each collated group 122 of items 102 from the collation platform.
[0067] The pedestal 140 may facilitate/assist with the sheathing of the
groups 122 of
items 102 with the erected case blanks 111C, as well as the closing of the
leading and trailing
bottom flaps F, G respectively of the erected case blanks 111C, as described
further
hereinafter. Accordingly, the leading and trailing flaps F, G of the erected
case blanks 111C
are moved into closed, support positions beneath the group 122 of items 102
that are
positioned within the interior storage space 107 of each erected case blank
111C. The
pedestal 140 may be associated with the first folding platform 163 and the
second folding
platform 165. Each of the first folding platform 163, the pedestal 140 and the
second folding
platform 165 may have upwardly directed support surfaces for supporting the
items 102
thereon. The positions of the support surfaces of the first folding platform
163, the pedestal
140 and the second folding platform 165 may be capable of limited vertical and
longitudinal
adjustment relative to each other.
[0068] Movement of successive groups 122 of items 102 across the pedestal
apparatus
140 may be achieved using the second cartesian robot 250-2.
[0069] As the group 122 of collated items 102 is being delivered, by the
header 116,
from the collation platform to the pedestal 140, a knocked-down, flattened
case blank 111A
may have already been retrieved, by the first cartesian robot 250-1, from, or
within, the blank
magazine 251. Through cooperation between the first cartesian robot 250-1 and
the second
17
Date Recue/Date Received 2022-12-30
cartesian robot 250-2, the flattened case blank 111A may be converted to an
erected case
blank 111C.
[0070] According to some aspects of the present application, the blank
magazine 251,
containing a stack of knock-down case blanks 111A, may be situated within an
operating
radius/reach of the first cartesian robot 250-1. A first end effector 252-1
may be mounted to
the first cartesian robot 250-1. Similarly, a second end effector 252-2 may be
mounted to the
second cartesian robot 250-2.
[0071] The first end effector 252-1 may be provided with a first set of
suction cups 313-
1. Similarly, the second end effector 252-2 may be provided with a second set
of suction cups
313-2. Vacuum forces may be generated at the suction cups 313-1, 313-2 in a
variety of
ways, including providing hoses delivering pressurized air to vacuum
generators mounted on
the end effector 252, with the vacuum generators interconnected to the suction
cups 313-1.
Electronic valves (not shown) that are part of the valve system 332 (FIG. 2)
under control of
the PLC 132 may be provided to control the flow of pressurized air to the
vacuum generators
and, thus, to control the vacuum at suction cups 313-1, 313-2. The electronic
valves may be
understood to allow for turning on and turning off of the vacuum generated at
the suction
cups 313-1, 313-2. It should be noted that, while many types of suction cups
313-1, 313-2
may be employed on the first end effector 252-1, a preferred type of suction
cup is the model
B40.10.04AB made by Piab AB of Danderyd, Sweden. Each suction cup 313-1, 313-2
may
be connected to an outlet from a vacuum generator. The vacuum generator may be
any
suitable vacuum generator device, such as, for example, the model VCH12-016C
made by
Pisco of Elk Grove Village, IL. Vacuum generators are known to have an inlet
interconnected
to a hose (not shown) that can carry pressurized air from an air compressor or
other vacuum
source to the vacuum generator. The vacuum generator converts the pressurized
air supplied
to the inlet port into a vacuum at one of the vacuum outlet ports. That vacuum
outlet port is
interconnected to one of the suction cups 313-1, 313-2 so that the suction cup
can have a
vacuum force. A solenoid valve device that is part of the valve system 332 may
be interposed
along the pressurized air channel running between each vacuum generator and
the source of
pressurized air. The solenoid valve device may, for example, be a model CPE14-
M1BH-5L-
1/8 made by Festo of Esslingen am Neckar, Germany. The valve system 332 is in
electronic
communication with the PLC 132 and controlled by the PLC 132. In this way, the
PLC 132
can turn on and turn off the supply of vacuum force to the suction cups 313-1,
313-2.
18
Date Regue/Date Received 2022-12-30
[0072] The first cartesian robot 250-1, with the first end effector 252-
1, under control of
the PLC 132, may be operable for successively picking up the knock-down flat
case blank
111A located at the case blank pick up position in the blank magazine 251,
rotating the flat
case blank 111A through 90 degrees, or so, and moving the flat case blank 111A
over to the
second cartesian robot 250-2. The second cartesian robot 250-2 may be shown to
assist in the
opening of the flat case blank 111A to form the erected case blank 111C. The
first cartesian
robot 250-1 may then release the erected case blank 111C, thereby allowing the
second
cartesian robot 250-2 to move the erected case blank 111C towards the pedestal
140.
[0073] When the group 122 of collated items 102 is located at the
pedestal 140, the
second cartesian robot 250-2 may manipulate the path of the second end
effector 252-2 and
the erected case blank 111C held by the second end effector 252-2, to sheath
the group 122 of
items 102 resting on the pedestal 140.
[0074] According to some aspects of the present application, the blank
magazine 251,
holding the knock-down flat case blanks 111A, may be configured to lift the
stack of flat case
blanks 111A to an operating height, such that the topmost flat case blank 111A
is always in a
specific position. According to other embodiments, the first end effector 252-
1 may be
equipped with an electronic eye sensor (not shown), such as the model 42KL-
D1LB-F4 made
by Allen-Bradley. The electronic eye sensor may be configured to detect the
position of the
top-most knock-down case blank 111A and generate signals for the PLC 132 to
follow a
specific path for movement of the first cartesian robot 250-1.
[0075] The first end effector 252-1 may engage with the knock-down case
blank 111A.
The first cartesian robot 250-1 may raise the first end effector 252-1,
thereby lifting the
knock-down case blank 111A vertically, that is, in the Z-direction. In
consequence of
vertically raising the knock-down case blank 111A, the knock-down case blank
111A may
begin to open up.
[0076] The first cartesian robot 250-1 may continue to move the knock-
down case blank
111A vertically upwardly while, concurrently moving the knock-down case blank
111A
horizontally, toward the pedestal 140, on which the group 122 of collated
items 102 is
located. Upon arrival at a location vertically above the pedestal 140, the
second cartesian
robot 250-2 may be moved, under control of the PLC 132, such that the second
set of suction
cups 313-2, of the second end effector 252-2, may engage the knock-down case
blank 111A
19
Date Regue/Date Received 2022-12-30
to, thereby, complete the opening of the knock-down blank 111A to become the
erected case
blank 111C with a substantially right-angle cross section. The first set of
suction cups 313-1
may then release their hold on the erected case blank 111C, thereby allowing
the first
cartesian robot 250-1 to return to the blank magazine 251 to pick up another
knock-down flat
case blank 111A.
[0077] The erected case blank 111C (having a configuration illustrated in
FIG. 3C) may
be moved, by the second end effector 252-2, to a preloading position (see FIG.
8) above the
pedestal 140, then to a fully engaged position (see FIG. 9) and then to a
fully loaded position
(see FIG. 11) with the group 122 of items fully located within the bounds of
the interior
storage space 107 of the erected case blank 111C. In this fully loaded
position, the erected
case blank 111C has been placed over the collated group 122 of items 102 while
the group
122 is positioned on the pedestal 140.
[0078] According to aspects of the present application, the erected case
blank 111C can
be placed in the pre-loading position and orientation (see FIG. 8) generally
above the pedestal
140 and at a vertical distance sufficiently above the uppermost surface of the
items 102 in the
group 122 to be loaded. Notably, in the initial pre-loading position (see FIG.
8), no portion of
the bottom edges of any of the bottom flaps J, K, F, G may be vertically below
the top surface
of the items 102. This initial pre-loading position (see FIG. 8) allows the
group 122 of items
to be moved onto the pedestal 140 with sufficient clearance to avoid contact
with any items
and/or cause any bottom flaps to become misaligned with their respective side
panels.
[0079] As the second cartesian robot 250-2 moves the second end effector
252-2 and,
consequently, the erected case blank 111C, vertically downwards, toward the
fully loaded
position (see FIG. 11), the fence 124 may be also be moved, under control of
the PLC 132,
vertically downwards away from the group 122 of items.
[0080] The second cartesian robot 250-2 may continue to move the second
end effector
252-2, and the erected case blank 111C held by the second end effector 252-2,
to fully sheath
the group 122 of items 102 with the erected case blank 111C. In this fully
loaded position
(see FIG. 11), the group 122 of items 102 is located entirely within the
interior storage space
107 of the erected case blank 111C and the side bottom flaps J and K (along
with bottom
leading flap F and the trailing bottom flap G) are all positioned below the
item support
surface of the pedestal 140.
Date Regue/Date Received 2022-12-30
[0081] Turning to FIGS. 10 and 11, the leading bottom flap F and the
trailing bottom
flap G of the erected case blank 111C may be folded about their joints with
panel A and panel
C, respectively, via horizontal, longitudinal movements across the pedestal
140.
[0082] The first folding platform 163, the second folding platform 165
and the pedestal
140 are illustrated as supported by a pedestal support frame.
[0083] By moving the erected case blank 111C right/longitudinally
rearward (away from
the output conveyor 170) using the second cartesian robot 250-2 moving the
second end
effector 252-2, the leading bottom flap F may be shown to be folded inwardly
onto the top
surface of the first folding platform 163 beneath the items, this motion being
assisted by a
first ramp 306r. At the same time, the trailing bottom flap G may be shown to
be folded
outwardly onto the top of the pedestal 140, while the trailing bottom flap G
is deflected
upwards with the assistance of a second ramp 310r. This motion is illustrated
between steps
S1900 and S1910 in FIG. 13.
[0084] Next, the first folding platform 163 and the second folding
platform 165 may be
raised, under control of the PLC 132, so their top support surfaces are at a
position slightly
higher than the support surface of the pedestal 140 (with the surface of the
second folding
platform 165 being raised slightly more than the surface of first folding
platform 163).
According to some aspects of the present application, the first folding
platform 163, the
second folding platform 165 and the pedestal 140 may all be similar in size.
The second
cartesian robot 250-2 moving the second end effector 252-2 may then shift the
erected case
blank 111C back to the left/forward (i.e., onto the pedestal 140) as
illustrated in step S1920.
[0085] As may be apparent in S1920, as the loaded case blank 111D shifts
onto the
pedestal 140, the trailing bottom flap G is folded back vertically downwards
to substantially
its starting orientation, perpendicular to the item support surfaces of the
pedestal 140. This
folding action is effected by the leading edge of the trailing bottom flap G,
catching a third
ramp 308r of the second folding platform 165 ¨ due to the surface of the
second folding
platform 165 having been raised to a position above the surface of the
pedestal 140 ¨ and
being directed/deflected downwards. The leading bottom flap F is illustrated
as being located
between the top surface of the pedestal 140 and the bottom surface of the
items.
[0086] Next, the first folding platform 163 may be lowered, under control
of the PLC
132, to a position where the support surface of the first folding platform 163
is slightly below
21
Date Recue/Date Received 2022-12-30
(e.g., approximately 0.5" below) the support surface of the pedestal 140 and
the second
cartesian robot 250-2 moving the second end effector 252-2, under control of
the PLC 132,
may act to shift the loaded case blank 111D forwards towards the second
folding platform
163, as illustrated as S1930. During this shift onto the second folding
platform 165, the
trailing bottom flap G may be shown to be deflected upwards and folded onto
the top surface
of the second folding platform 165 beneath the items, this motion being
assisted by the third
ramp 308r, such that the loaded case blank 111D and the bottom flaps F, G,
reach the position
illustrated as S1930. In this position, the trailing bottom flap G is now also
folded
horizontally inwards and is perpendicular relative to the vertical side walls
of the loaded case
blank 111D. The trailing bottom flap G is located between the top surface of
the first folding
platform 163 and the bottom surface of the items.
[0087] In a final movement of the sequence, the second folding platform
165 may be
moved, under control of the PLC 132, so that the support surface of the second
folding
platform 165 is in a slightly raised position higher (e.g., approximately 0.5"
higher) than the
support surface of the pedestal 140 and the second cartesian robot 250-2
moving the second
end effector 252-2 may act to shift the loaded case blank 111D rearward to be
located
completely upon the surface of the pedestal 140, such that, during the shift
rearward, the
trailing bottom flap G is maintained in a horizontal position and the leading
edge of the
trailing bottom flap G catches the second ramp 310r of the pedestal 140.
[0088] Thus, as shown in S1940, when the loaded case blank 111D and the
items 102
contained therein are centrally located on the support surface of the pedestal
140, the leading
bottom flap F and the trailing bottom flap G have been both folded
horizontally inwards and
are perpendicular relative to the vertical side walls of the loaded case blank
111D. The
leading bottom flap F is located between the top surface of the pedestal 140
and the bottom
surface of the items. The trailing bottom flap G is located between the top
surface of the
pedestal 140 and the bottom surface of the items. The result is that the
bottom flaps F and G
have both been moved into an operationally closed supporting position beneath
the rows of
items 102.
[0089] Variations of the foregoing sequential movements of the loaded
case blank 111D
and the bottom flaps F, G, relative to the first folding platform 163, the
pedestal 140 and the
second folding platform 165 are possible. For example, in a first movement of
the loaded
case blank 111D effected by the second cartesian robot 250-2 moving the second
end effector
22
Date Recue/Date Received 2022-12-30
252-2, the loaded case blank 111D may be moved forwards onto the second
folding platform
165 by a sufficient forward distance to place the trailing bottom flap G
between the bases of
the items and the surface of the second folding platform 165. This may be
assisted by the
leading edge of the bottom flap G catching the third ramp 308r. This movement
may also
cause the leading bottom flap F to become angled upwards from the vertical
downwards
direction and outwards.
[0090] In a second movement of the loaded case blank 111D effected by the
second
cartesian robot 250-2 moving the second end effector 252-2, the loaded case
blank 111D may
be moved rearwards, back onto the pedestal 140, allowing the leading bottom
flap F to drop
down. The second folding platform 165 may have been raised sufficiently
relative to the
pedestal 140 to ensure trailing bottom flap G catches the second ramp 310r and
is positioned
between the bases of the items and the surface of the pedestal 140 during this
rearward
movement.
[0091] In a third movement of the loaded case blank 111D effected by the
second
cartesian robot 250-2 moving the second end effector 252-2, the loaded case
blank 111D may
be moved rearwards from the pedestal 140 onto the first folding platform 163,
allowing
leading bottom flap F to be folded upwards and inwards. The first folding
platform 163 may
have been lowered sufficiently relative to the pedestal 140 to ensure the
trailing bottom flap
G catches the first ramp 306r and moves between the bases of rearward row(s)
of the items
102 and the support surface of the first folding platform 163 during this
rearward movement.
After this movement, the result is that the bottom flaps F and G have both
been moved into
an operationally closed supporting position beneath the rows of items 102.
[0092] After having the bottom flaps F and G moved to the closed
position, the bottom-
loading of the collated items 102 into the erected case blank 111C may be
considered to be
complete such that the loaded case blank 111D is the result. Subsequent
movement, by the
second cartesian robot 250-2, may act to move the loaded case blank 111D, held
by the
second end effector 252-2 and containing the collated items 102 in the
interior storage space
107, to the output conveyor 170. At the output conveyor 170, the second end
effector 252-2
may release the loaded case blank 111D, thereby allowing the output conveyor
170 to move
the loaded case blank 111D through further processing.
23
Date Recue/Date Received 2022-12-30
[0093] As the second end effector 252-2 releases the loaded case blank
111D, a kicker
arm of the second end effector 252-2 may rotate/articulate, thereby folding
the trailing flap H
forward, so that the trailing flap H will be subsequently engaged by a
generally flat and thin,
longitudinally extending compression plate 408 (see FIG. 10).
[0094] The output conveyor 170 may be configured to receive the loaded
case blank
111D having the leading bottom flap F and the trailing bottom flap G
appropriately folded
and with the group 122 of items 102 held within the interior storage space 107
defined by the
panels A, B, C, Z of the loaded case blank 111D. Next, the remaining bottom
flaps (side flaps
J and K) may be closed. The closing of the remaining bottom flaps may be shown
to be made
relatively straightforward, since leading bottom flap F and the trailing
bottom flap G are
already closed and may be shown to provide support surfaces for holding the
items 102
within the interior space 107 of the loaded case blank. In some aspects of the
present
application, wherein the top flaps were not closed previously, the system 100
of FIG. 1 may
be configured to close the top flaps E, I, H, L. Additionally, the loaded case
blank 111D may
be sealed in a manner that seals the group 122 of items 102 within the
interior storage space
107 of the loaded case blank 111D.
[0095] As the output conveyor 170 transports the loaded case blank 111D
past the
compression plate 408 may place the leading top flap E in the closed position.
Once both the
leading top flap E and the trailing top flap H have been placed in the closed
position, these
flaps E, H may also be maintained in the closed position by the compression
plate 408.
[0096] With reference to FIG. 10, the bottom side flaps J, K may be
folded using a pair
of bottom rails 410, positioned on an underside of the output conveyor
platform. The bottom
rails 410 may be implemented as two, generally tubular shapes (i.e., an
elongated rounded
rod or tube). The bottom rails 410 may formed to have two portions, a first
portion 410-r
being a downstream, inwardly angled input portion configured to contact the
flaps J, K, and a
second portion 410-p of the bottom rails 410 being configured in parallel. As
the output
conveyor 170 transports the loaded case blank 111D along the first portion 410-
r of the
bottom rails 410, the bottom flaps J, K may be moved inward alongside the
angle of the first
portion 410-r. At the nexus of first portion 410-r and the second portion 410-
p, the bottom
flaps will be fully closed.
24
Date Recue/Date Received 2022-12-30
[0097] Also in view of FIG. 10, a pair of top flap rails 412 may be
employed to fold the
top side flaps I, L through the movement of the loaded case blank 111D by the
output
conveyor 170. The top flap rails 412 may be formed having two portions, a
first portion 412-r
being an angled downstream, inwardly angled input portion configured to
contact the flaps I,
L, and a second portion 412-p of the tubes narrowing to an individual point.
As the output
conveyor 170 transports the loaded case blank 111D along the first portion 412-
r of the top
flap rails 412, the top flaps I, L may be moved inward alongside the angle of
the first portion
412-r. At the nexus of the first portion 412-r and the second portion 412-p,
the top flaps I, L
will fully close and the case will have traversed outside of the compression
plate 408. It
should be noted that these folding apparatuses may be able to process a
variety of different
sized case blanks without adjustment. However, the components of these folding
apparatuses
may also be mounted to the frame 115 in a manner that allows their positioning
to be readily
adjusted to accommodate different sized case blanks.
[0098] After the top and bottom major flaps have been folded, the loaded
case blank
111D may be sealed at both top and bottom ends along their top and
longitudinal central flaps
joints, using a sealing mechanism (not shown).
[0099] The components of the system 100 of FIG. 1, and parts thereof,
that are described
herein, may be made from generally available materials. For example, some
components, or
parts thereof, may be made of suitable metals such as steel and/or aluminum,
as will be
evident to a person skilled in the art, when reading the present disclosure.
[0100] FIG. 14 illustrates a flow-chart diagram describing a method M1000
of filling and
sealing cases. The method M1000 may be performed by the system 100 of FIG. 1,
described
hereinbefore.
[0101] At step S100, an input flow of items 102 is received, such as from
the
input/infeed conveyor 104. The input flow of items 102 may be received in a
single line.
[0102] At step S200, subgroups/rows of items are transferred from the
input flow to a
collating station to form a collated group. This may be carried out, for
example, by the header
116.
[0103] At step S300, a collated group is transferred from the collating
station to the
pedestal 140. The transfer may be done using the header 116. The header 116
may be
Date Regue/Date Received 2022-12-30
controlled to slide the group 122 of collated items 102 to the pedestal 140,
surrounded on
three sides by the fence 124.
[0104] At step S400, the first cartesian robot 250-1 may select a knock-
down flat case
blank 111A from the blank magazine 251.
[0105] In step S500, the case is erected. That is the knock-down blank
111A is caused to
become the erected case blank 111C. as discussed hereinbefore, the second
cartesian robot
250-2 may be moved, under control of the PLC 132, such that the second set of
suction cups
313-2, of the second end effector 252-2, may engage the knock-down case blank
111A held
by the first end effector 252-1 of the first cartesian robot 250-1.
[0106] At step S600, the second cartesian robot 250-2 may act to sheath
the collated
group with the erected case blank 111C while the fence 124 moves vertically
downward. The
second cartesian robot 250-2 may hold the erected case blank 111C to approach
the collated
group 122 of items 102 from above, thereby allowing for the bottom flaps to
remain open and
providing clearance space for sheathing of the group 122 by the erected case
blank 111C.
[0107] At step S700, using the second cartesian robot 250-2, the leading
bottom flap and
the trailing bottom flap may be folded. The second cartesian robot 250-2 may
move the
loaded case blank 111D forward and rearward in relation to the pedestal 140.
The pedestal
140 may be bracketed by platforms, wherein each platform may include a ramp
portion and a
flat portion. Each of the platforms may be linearly actuated in a vertical
axis to allow the
platforms to be raised above or lowered below the pedestal 140. Using the
method as
described with relation to FIG. 13, the bottom flaps may be folded under the
individual items
102.
[0108] At step S800, the bottom side flaps and all top case flaps may be
closed. This may
be performed by delivering the case to the output conveyor 170. The output
conveyor 170
may be configured to transport the case across a first rail to close the top
leading flap and the
top trailing flap. A kicker arm may be configured to assist in closing the top
trailing minor
flap. The top minor flaps may be held in place by a compression plate. Then,
top rails and
bottom rails may be employed to close the top side flaps and the bottom side
flaps. Once
closed, the loaded case blank 111D may be fed through a top and bottom case
joint sealer,
configured to apply a strip of tape or adhesive to the top or bottom of the
case along the
exposed central flaps joints on the top and bottom of the case.
26
Date Recue/Date Received 2022-12-30
[0109] It is expected that, in some aspects of the present application,
the system 100 may
be capable of erecting, loading and sealing in the range of approximately 10
case blanks per
minute and, possibly, about 15 case blanks per minute or more, depending upon
configuration
of the specific case blanks, items/group of items and specific components of
the system 100
of FIG. 1.
[0110] Of course, the above described embodiments are intended to be
illustrative only
and in no way limiting. The described embodiments of carrying out the
invention are
susceptible to many modifications of form, arrangement of parts, details and
order of
operation. The invention, rather, is intended to encompass all such
modification within its
scope, as defined by the claims.
[0111] Selected aspects of the present application may be used in a
variety of fields and
applications. Other features, modifications and applications of the
embodiments described
here may be understood by those skilled in the art in view of the disclosure
herein.
[0112] It will be understood that any range of values herein is intended
to specifically
include any intermediate value or sub-range within the given range and all
such intermediate
values and sub-ranges are individually and specifically disclosed.
[0113] The word "include" or its variations such as "includes" or
"including" will be
understood to imply the inclusion of a stated integer or groups of integers
but not the
exclusion of any other integer or group of integers.
[0114] It will also be understood that the word "a" or "an" is intended
to mean "one or
more" or "at least one" and any singular form is intended to include plurals
herein.
[0115] It will be further understood that the term "comprise," including
any variation
thereof, is intended to be open-ended and means "include, but not limited to,"
unless
otherwise specifically indicated to the contrary.
[0116] When a list of items is given herein with an "or" before the last
item, any one of
the listed items or any suitable combination of two or more of the listed
items may be
selected and used.
[0117] It should be appreciated that one or more steps of the embodiment
methods
provided herein may be performed by corresponding units or modules. For
example, data
27
Date Regue/Date Received 2022-12-30
may be transmitted by a transmitting unit or a transmitting module. Data may
be received by
a receiving unit or a receiving module. Data may be processed by a processing
unit or a
processing module. The respective units/modules may be hardware, software, or
a
combination thereof. For instance, one or more of the units/modules may be an
integrated
circuit, such as field programmable gate arrays (FPGAs) or application-
specific integrated
circuits (ASICs). It will be appreciated that where the modules are software,
they may be
retrieved by a processor, in whole or part as needed, individually or together
for processing,
in single or multiple instances as required, and that the modules themselves
may include
instructions for further deployment and instantiation.
[0118] Although a combination of features is shown in the illustrated
embodiments, not
all of them need to be combined to realize the benefits of various embodiments
of this
disclosure. In other words, a system or method designed according to an
embodiment of this
disclosure will not necessarily include all of the features shown in any one
of the Figures or
all of the portions schematically shown in the Figures. Moreover, selected
features of one
example embodiment may be combined with selected features of other example
embodiments.
[0119] Although this disclosure has been described with reference to
illustrative
embodiments, this description is not intended to be construed in a limiting
sense. Various
modifications and combinations of the illustrative embodiments, as well as
other
embodiments of the disclosure, will be apparent to persons skilled in the art
upon reference to
the description. It is therefore intended that the appended claims encompass
any such
modifications or embodiments.
28
Date Recue/Date Received 2022-12-30
