BACKGROUND

The present disclosure relates to vibration or rocking of containers, boxes, or Gaylord containers.

In certain situations, it is desirable to vibrate or rock a container, box, or gaylord to induce the contents of the container or box to settle. However, current electrical vibration tables have a high monetary cost. In addition, the container/box can “walk off” the vibration table if purely vertical motion is used for vibration, creating a safety hazard.

It would be desirable to provide systems and methods to overcome this problem and others.

BRIEF DESCRIPTION

The present disclosure relates to a vibratory unit or compaction device, which is used to induce the smaller contents within a large container to settle. For example, smaller items become packed more tightly within the large container such that any free space between them is reduced, and the majority of free space is concentrated at the top of the large container. This permits additional smaller items to be placed into the large container, increasing packing efficiency and reducing the number of large containers needed for a given number of smaller items. This also improves the balance of the large container, and reduces the asymmetry of the weight within the large container.

In addition, in the past, associates have tried to “flex” the side of the large container to help settle the smaller items therein and increase the capacity of the large container. But in some instances, the side of the large container (which is made of cardboard) rips and the associate falls backwards, causing injuries such as broken arms or wrists when they hit the floor. A “reach tool” can be used to reach into the large container to help even out the smaller items, but this can take additional time. The use of the vibratory unit or compaction device results in an increased number of smaller items that can be shipped in the large container, reduced time to accomplish the packing task, and increased worker safety through the use of an engineered solution.

Disclosed in various embodiments are compaction devices including: an upper structure configured to hold a container; a base structure configured to be connected to the upper structure through two front end pivot linkages, and two rear end pivot linkages; and a pneumatic cylinder configured to convey motion to the upper structure. The two front end pivot linkages may have a different length than the two rear end pivot linkages.

In some embodiments, the two front end pivot linkages are longer than the rear end pivot linkages. In some embodiments, the two rear end pivot linkages are longer than the front end pivot linkages. In some embodiments, in a resting position: the front end pivot linkages each have a longitudinal axis perpendicular to a lower edge of the base structure; and the rear end pivot linkages each have a longitudinal axis that form an acute angle with the lower edge of the base structure. In some embodiments, in a resting position: the rear end pivot linkages each have a longitudinal axis perpendicular to a lower edge of the base structure; and the front end pivot linkages each have a longitudinal axis that form an acute angle with the lower edge of the base structure. In some embodiments, the pneumatic cylinder is a first pneumatic cylinder, and the compaction device further comprises a second pneumatic cylinder.

In another aspect, disclosed herein are compaction methods for operating a compaction device, comprising: using a pneumatic cylinder to cause an upper structure to move. The upper structure is connected to a base structure through two front end pivot linkages, and two rear end pivot linkages; and the two front end pivot linkages have a different length than the two rear end pivot linkages.

In some embodiments, the two front end pivot linkages are longer than the rear end pivot linkages. In some embodiments, the two rear end pivot linkages are longer than the front end pivot linkages. In some embodiments, in a resting position: the front end pivot linkages each have a longitudinal axis perpendicular to a lower edge of the base structure; and the rear end pivot linkages each have a longitudinal axis that form an acute angle with the lower edge of the base structure. In some embodiments, in a resting position: the rear end pivot linkages each have a longitudinal axis perpendicular to a lower edge of the base structure; and the front end pivot linkages each have a longitudinal axis that form an acute angle with the lower edge of the base structure. In some embodiments, the pneumatic cylinder is a first pneumatic cylinder, and the compaction device further comprises a second pneumatic cylinder.

In yet other aspects, disclosed are methods for balancing an asymmetric load of a product, comprising: placing a container with the asymmetric load in an upper structure, wherein the container has a greater amount of the product located closer to a non-loading end of the upper structure than closer to a loading end of the upper structure; and using a pneumatic cylinder to convey motion to the upper structure. The upper structure is connected to a base structure by two front end pivot linkages and two rear end pivot linkages; and the two rear end pivot linkages are longer than the two front end pivot linkages so that the two rear end pivot linkages convey a greater amplitude of motion to the upper structure than the two front end pivot linkages.

Also disclosed are compaction devices, including: an upper structure configured to hold a container; a base structure configured to connect to the upper structure through: (i) a loading end upper toggle pivot linkage connected to a loading end lower toggle pivot linkage, and (ii) a non-loading end upper toggle pivot linkage connected to a non-loading end lower toggle pivot linkage; a pull arm configured to connect the loading end upper and lower toggle pivot linkages to the non-loading end upper and lower toggle pivot linkages; and a pneumatic cylinder configured to convey motion to the upper structure through the pull arm.

In some embodiments, devices as described in the preceding paragraph further include: a first cam follower connected to the base structure, wherein the first cam follower is configured to guide the base structure by moving along a first flat surface. The device may further include a second cam follower connected to the base structure, wherein the second cam follower is configured to guide the base structure by moving along a second flat surface. The first flat surface may be at an 85° angle with a lower edge of the base structure. In some embodiments, the base structure comprises first side and a second side; the loading end upper toggle pivot linkage is a first side loading end upper toggle pivot linkage; the loading end lower toggle pivot linkage is a first side loading end lower toggle pivot linkage; the non-loading end upper toggle pivot linkage is a first side non-loading end upper toggle pivot linkage; the non-loading end lower toggle pivot linkage is a first side non-loading end lower toggle pivot linkage; the pull arm is a first side pull arm; the pneumatic cylinder is a first side pneumatic cylinder; and the compaction device further comprises: a second side loading end upper toggle pivot linkage connected to a second side loading end lower toggle pivot linkage; a second side non-loading end upper toggle pivot linkage connected to a second side non-loading end lower toggle pivot linkage; a second side pull arm configured to connect the second side loading end upper and lower toggle pivot linkages to the second side non-loading end upper and lower toggle pivot linkages; and a second side pneumatic cylinder configured to convey motion to the upper structure through the second side pull arm. In some embodiments, the loading end upper toggle pivot linkage, the loading end lower toggle pivot linkage, the non-loading end upper toggle pivot linkage, and the non-loading end lower toggle pivot linkage each have an equal length. In some embodiments, the toggle joints are configured to convey the motion to the upper structure such that the motion is linear.

Also disclosed in various embodiments are compaction devices, comprising: an upper structure configured to hold a container; a base structure connected to the upper structure through a first front end pivot linkage and a first rear end pivot linkage; and a first actuator configured to convey motion to the upper structure; wherein the first front end pivot linkage has a different length from the first rear end pivot linkage.

In some embodiments, the first front end pivot linkage is longer than the first rear end pivot linkage. In other embodiments, the first rear end pivot linkage is longer than the first front end pivot linkage.

In some embodiments, in a resting position: the first front end pivot linkage has a longitudinal axis perpendicular to a lower edge of the base structure; and the first rear end pivot linkage has a longitudinal axis that forms an acute angle with the lower edge of the base structure.

In other embodiments, in a resting position: the first rear end pivot linkage has a longitudinal axis perpendicular to a lower edge of the base structure; and the first front end pivot linkage has a longitudinal axis that forms an acute angle with the lower edge of the base structure.

In particular embodiments, the first actuator is in the form of a pneumatic cylinder. Additional actuators and pneumatic cylinders can also be present.

The upper structure of the compaction device may comprise a floor and three vertical sidewalls extending perpendicularly from the floor on a first side, a second side, and a rear side of the upper structure. The first front end pivot linkage and the first rear end pivot linkage may be connected to the vertical sidewall on the first side of the upper structure, with the first actuator conveying motion proximate the first side of the upper structure. In particular embodiments, the compaction device can further comprise: a second front end pivot linkage and a second rear end pivot linkage connected to the vertical sidewall on the second side of the upper structure and connected to the base structure; and a second actuator that conveys motion proximate the second side of the upper structure; wherein the first front end pivot linkage and the second front end pivot have the same length; and wherein the first rear end pivot linkage and the second rear end pivot have the same length.

In some embodiments, the compaction device further comprises an adapter mounted upon the vertical sidewall of one or both sides of the upper structure, the adapter(s) configured to reduce an effective width of the upper structure. The adapter may comprise an outer bracket, an inner bracket, at least one displacement arm, and a locking arm for fixing the outer bracket and the inner bracket relative to each other. In particular embodiments, a retainer lock device is present on one end of the inner bracket. The retainer lock device rotates around a longitudinal axis of the inner bracket, and can be used to hold a container against the rear sidewall of the upper structure. A clamp mounted upon the inner bracket engages the retainer lock device in two different positions.

The compaction device can further comprise a toe guard on a front side of the upper structure.

The base structure may comprise a rear housing for the first actuator; a first sidewall; and a second sidewall; wherein the upper structure is located between the first sidewall and the second sidewall of the base structure.

The compaction device can also further comprise a first side guard and a second side guard attached to the upper structure, such that the first sidewall and the second sidewall of the stationary base structure are located between the upper structure and the side guards.

The compaction device may further comprise a control system for controlling the first actuator. The control system can be located proximate a rear end of the base structure, and the device may further comprise a pushbutton for activating the control system which is located proximate a front end of the base structure. In embodiments, generally, the base structure has a larger footprint than the upper structure.

Also disclosed are various methods for operating a compaction device, comprising: placing a container with an asymmetric load in an upper structure of the compaction device; and using at least a first actuator to cause the upper structure to move; wherein the compaction device has a structure as described herein.

Also disclosed herein are compaction devices, comprising: an upper structure configured to hold a container, a first side of the upper structure being connected to a first front end upper toggle pivot linkage and a first rear end upper toggle pivot linkage; a base structure, a first side of the base structure being connected to a first front end base toggle pivot linkage and a first rear end base toggle pivot linkage; a first pull arm connected to the first front end upper toggle pivot linkage, the first front end base toggle pivot linkage, the first rear end upper toggle pivot linkage, and the first rear end base toggle pivot linkage; and a first actuator connected to the first pull arm for conveying motion to the upper structure.

In some embodiments, the compaction device further comprises a primary cam follower connected to a first side of the upper structure, wherein the primary cam follower is configured to guide the upper structure by moving along a flat surface of a primary cam located on a first side of the base structure. The flat surface of the primary cam can form an angle of about 60° to 88° angle with a lower edge of the base structure.

In further embodiments, the primary cam is proximate a front end of the base structure, and the compaction device further comprises a secondary cam follower connected to the first side of the upper structure, wherein the secondary cam follower moves along a surface of a secondary cam located on the first side of the base structure. In more specific embodiments, the flat surface of the primary cam forms a primary angle with a lower edge of the base structure, and wherein the flat surface of the secondary cam forms a secondary angle with the lower edge of the base structure, and wherein the primary angle is different from the secondary angle.

The first front end upper toggle pivot linkage, the first front end base toggle pivot linkage, the first rear end upper toggle pivot linkage, and the first rear end base toggle pivot linkage may be of equal length.

In further embodiments, the compaction device may have a structure wherein: a second side of the upper structure is connected to a second front end upper toggle pivot linkage and a second rear end upper toggle pivot linkage; a second side of the base structure is connected to a second front end base toggle pivot linkage and a second rear end base toggle pivot linkage; a second pull arm is connected to the second front end upper toggle pivot linkage, the second front end base toggle pivot linkage, the second rear end upper toggle pivot linkage, and the second rear end base toggle pivot linkage; and a second actuator is connected to the second pull arm for conveying motion to the upper structure.

The upper structure of the compaction device may comprise a floor and three vertical sidewalls extending perpendicularly from the floor on a first side, a second side, and a rear side of the upper structure.

These and other non-limiting characteristics are more particularly described below.

