TECHNICAL FIELD

The present invention is generally directed to automated case packing operations and one or more of processing lines, systems, machines, apparatuses, assemblies, subassemblies, for/of any or all of case set up, case packing and/or loaded case closure, more particularly, to systems characterized by robotic case set up, robotic case packing and/or robotic loaded case closure operations.

BACKGROUND

Automated robotic case packing operations are characterized by case set up (i.e., at least partially erecting a case from a case blank sourced from a source of case blanks such as a magazine or pallet of case blanks or the like), case filing/loading (i.e., introducing articles/product into the partially erect case), and case closure (i.e., securingly housing/containing the product within or in relation to the case to create a package). Cases may generally comprise trays, wrap around, or knock down styles with case loading operations comprising top load, horizontal load or bottom load, the nature of the case style and filing operation being a function of, among other things, the nature of the product.

Numerous teachings directed to robotic case packing are known with a considerable number of intermittent motion case packers commercially available. For example, Boisseau (U.S. Pat. Nos. 4,870,428), Focke et al. (6,006,493), Bellante (8,387,349), Poutot (8,671,651), and Wintring et al. (US Pat. Appl. 2007/0204567) generally disclose machines for case set up, case loading and case closure operations, however, each generally emphasize a single aspect (i.e., operation) of the overall packer functionality.

Boisseau discloses a readily adjustable packing machine, capable of top or side case loading operations, characterized by a robust mechanical case erecting station. After transfer of a blank to sets of drive lugs via a pivot arm (FIG. 5phantom), a pivotable set up arm28, carried on shaft27(FIG. 1;FIG. 10), attaches from above to a side of the case to open it, thereafter, the case bottom is formed between positions24&25(FIG. 1, 2) via combined operation of flap folding arms35,36, sticking means39(FIG. 2) and plate40driven by jack41(FIG. 3) to effectuate case erection.

Focke et al. disclose conventional means for erecting a case from a blank (FIG. 1) and use of a special lifting conveyor (FIGS. 4-7) traversing accumulation station20and top load station19(FIG. 1). A lifting head18is connected to a toothed belt22via arm34, the belt carrying the lifting head from station to station. Via a lever parallelogram35, articulators and a horizontally translatable guided carriage42, the lifting head may ascend and descend at the receiving and loading stations.

Bellante (CAMA1, S.p.A (IT)) discloses a machine characterized by a case forming section, a case loading section, and a loaded case closure/sealing station, the loaded case closing station being fed directly by the box translation system (FIG. 1), for instance by a servo-train conveyor (FIGS. 5 & 6), or a translation system comprising a plurality of linear conveyors independent of each other. The loaded case closing station (FIG. 3) characterized by carriage301which translatingly supported on track302for movement there along in a process flow direction, the carriage in turn translatingly supporting tool or head300on beam303for movement there along in a vertical direction (i.e., an ascending/descending motion relative to an underlying loaded case). The tool includes frame310, an actuatable clamp312hingedly supported thereby for closure of front flap104of box lid102(FIG. 4), and a retainer316which works in conjunction with actuatable stop317to hold the case for lid/flap closure via the pivot clamp. After lid closure, the case is released and lid flaps103are thereafter operated upon by downstream guides (FIG. 9a-9c).

Poutot discloses a machine (FIG. 1) characterized by Selective Compliance Assembly Robot Arms or Selective Compliance Articulated Robot Arms (SCARAB) to effectuate blank transfer (16), case filling (22,128) and/or case grouping (130) and filling (135), and filled case closure (24). Robotic arm16picks a series of adjacent blanks from magazine14and urges them into adjacent preforming dies18for set up, a feeder removes the partially formed cartons from the pre-former and to carton conveyor19. An article stream is increasingly adjusted from two lanes via manipulator12, with gripper heads54of a robotic an end of arm tool (EOAT) of carton filling robotic arm22(FIG. 4) securing articles for case loading, the EOAT comprising a coupling head50, a moving head52supported thereby, and the gripper heads coupled to the moving head. The moving head is translatable relative to the coupling head (i.e., in the direction of process flow), with the gripper heads capable of moving with respect to each other. Further operational modes contemplate a second loader128to supplement the first loader (FIG. 9), or use of a primary grouping device130for transfer of cases P to a station for loading into cases C by loader135(FIGS. 10 & 11).

Finally, Wintring et al. disclose a top load cartoner wherein blanks are reciprocatingly passed to former robot22(FIG. 1) which advances an array of blanks through a gluing station and then to a forming die station28wherein the former presses/plunges the blanks onto the forming dies. After overhead loading via conventional means at station33, the filled cases may have glue applied at station44and thereafter pass through fixed guide work for flap folding, with robot36vertically passing the loaded cases through static dies for top closure.

With increasing processing demands, for instance and without limitation, higher speed/throughput, greater reliability, improved repeatability, enhanced versatility, reduced downtime (e.g., for maintenance and/or change parts), reduced factory floor space, etc., a platform or modular approach remains advantageous and desirable. While improvements in any of the case set up, case loading or loaded case closure operations are no doubt warmly welcomed, a reimagined machine/processing approach characterized by, among other things, a smaller footprint, an increased operational functionality without increasing overall machine size, fewer parts, especially operator friendly operations/assemblies, operations upon either wrap around or knock down cases, positive case placement and retention throughout all operational steps, a fixedly positioned (e.g., fixed height) case blank magazine, an ability of a case set up assembly to secure cases from either of an in-line magazine or vertical magazine (i.e., cases stacked parallel to the floor), precise operational timing, and effectuation of variable travel paths for supremely efficient and effective operational engagements and selectively sustainable engagements are believed ultimate aims.

SUMMARY OF THE INVENTION

A robotic case packer is provided. The packer, in the form of a system, advantageously, but not necessarily, as a module or platform, includes a case conveying apparatus, a case set up station, a case loading station, and a loaded case closure station, the case conveying apparatus receiving and conveying a case blank for case set up, case loading and loaded case closure operations, a process flow path as to case operations delimited by the case conveying apparatus. The case set up station is characterized by a case set up robot operable in a process flow path direction, the case set up robot securing a case blank from a source of case blanks and transferring the blank to the case conveying apparatus. The case loading station is characterized by a case loading robot operable across the process flow path direction, the case loading robot transferring an article group for case loading into a set up case conveyed by the case conveying apparatus. Finally, the case closure station is characterized by a loaded case closure robot operable in the process flow path direction, the case closure robot effectuating a compressed sealed closure of a loaded case conveyed by the case conveying apparatus.

As to the robots of the contemplated packer, three axis robots advantageously aid case set up and loaded case closure operations, with two axis robots aiding case loading, and suitably aiding case closure operations in lieu of a preferred three axis robot. In a preferred embodiment, the robots are Selective Compliance Assembly Robot Arms or Selective Compliance Articulated Robot Arms (SCARAs). In a further, alternate embodiment, a two axis Cartesian robot may be suitably substituted for the SCARA, e.g., a linear servo driven pusher. Further still, in yet a further alternate embodiment, an additional, second SCARA loaded case closure robot is provided. Notionally, the robots carry tools, i.e., end of arm tools (EOATs) or end effectors.

EOATs may be fixedly carried by the robot, or otherwise carried thereby, for example and without limitation, pivotably or rotatingly carried by/at a free end of the robot. The case up robot is adapted to carry a tool for either of engagement of a knock down case blank or a wrap around case blank, advantageously, a pivotable tool. Moreover, while tools corresponding to each of the case loading and loaded case closure robots may be pivotably or rotatingly carried by/at a free end of the robot, they need not be.

As to case set up, and in a preferred knock down case blank processing embodiment, the case set up robot advantageously, but not necessarily, carries a tool actuatable for cooperative engagement with adjacent portions of such case blank. In a preferred wrap around case blank processing embodiment, the case set up robot advantageously, but not necessarily, pivotably carries a forming die tool characterized by retractable suction cups to secure a case blank from a supply of case blanks. More particularly, the forming die tool includes a frame, a major panel, a minor panel, and retractable vacuum cups to secure the case blank in relation to the major panel of the tool, the panels orthogonally adjacent each other in respect of the frame, the major panel adapted to permit retraction of the vacuum cups there through.

As to case loading, in a preferred embodiment, the case loading robot advantageously, but not necessarily, carries a tool comprising a paddle or the like to sufficiently engaged an article group formed from articles of an article infeed conveyor or the like. The tool engaged article group is thereafter transferred to an adjacent case via robot actuations in furtherance of forming a loaded case.

As to loaded case closure, the case closure robot carries a tool for effectuating a compressed sealed closure of the loaded case conveyed by the conveying apparatus, advantageously, but not necessarily the tool is pivotingly or rotatingly carried thereby. Advantageously, the case closure robot initially animates the tool for travel in a counter process flow path direction to initially engage the loaded case, and thereafter animates the tool for travel in a process flow direction with the loaded case so travelling within the case loading station, and, further still, desirably and optionally, thereafter animating the tool for travel in a process flow direction with the loaded case so travelling through and from the case loading station.

Case blanks for the formation of, without limitation, wrap around cases or knock down cases, are sourced from a magazine, pallet, etc. Advantageously, case blank magazines are contemplated, the magazines preferably but not necessarily being non-indexing types, with in-line and vertical (i.e., flat stack) magazines being equally suitable.

The case conveying apparatus may be of conventional form/design. A conveyor of the apparatus is advantageously a flighted or lugged conveyor, more particularly, either of a flighted or lugged endless belt or chain. Flight adjustability is provided for, with the conveyor adapted for servo driven flight adjustment. Alternately, the case conveying apparatus may take the form of a walking beam conveyor.

In addition to the case conveying apparatus and note operation stations, a preferred robotic case packer is further characterized by a tool bar for effectuating, among other things, case flap manipulations during progressive conveyance of the case blank upon the case conveying apparatus. Advantageously, but not necessarily, the tool bar may include, among other things, flap traps, funnels/ploughs, tuckers, an adhesive dispensing assembly, and a lower loaded case compression assembly/apparatus. Moreover, mechanized elements or components of the tool bar are advantageously readily adjustable, as for instance, via the inclusion of linear actuators as part of a control system or module as to the packer or component. More specific features and advantages obtained in view of the summarized features will become apparent with reference to the drawing figures and DETAILED DESCRIPTION OF THE INVENTION.

