US20090056276A1 - System and method for packaging article layers - Google Patents
System and method for packaging article layers Download PDFInfo
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- US20090056276A1 US20090056276A1 US11/849,619 US84961907A US2009056276A1 US 20090056276 A1 US20090056276 A1 US 20090056276A1 US 84961907 A US84961907 A US 84961907A US 2009056276 A1 US2009056276 A1 US 2009056276A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B9/00—Enclosing successive articles, or quantities of material, e.g. liquids or semiliquids, in flat, folded, or tubular webs of flexible sheet material; Subdividing filled flexible tubes to form packages
- B65B9/02—Enclosing successive articles, or quantities of material between opposed webs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B21/00—Packaging or unpacking of bottles
- B65B21/02—Packaging or unpacking of bottles in or from preformed containers, e.g. crates
- B65B21/025—Packaging or unpacking of bottles in or from preformed containers, e.g. crates the bottles being arranged in a head-to-bottom formation
Definitions
- the present invention is directed to a system and method for packaging article layers, and specifically to a system and method for packaging article layers for articles having substantially non-uniform geometries.
- the article When large numbers of stackable articles must be transported in large quantities to another location, especially when the article is small, the article may be packaged in a container to protect the article during shipping of the container. Alternately, to reduce the amount of handling required, the articles may be arranged in a tight grouping, or array of articles.
- Each array of articles can form a layer of articles that can be stacked on a pallet having a footprint which can be accommodated by freight hauling compartments, e.g., for truck, rail, sea or air vessels.
- Palletizing articles is becoming increasingly automated in manufacturing facilities, wherein articles are moved via a conveyor, which articles are manipulated by robots onto pallets. Such processing may work well if the articles are inherently stable, i.e., having a broad base footprint and low center of gravity, which articles being resistant to tipping.
- the articles are inherently stable, i.e., having a broad base footprint and low center of gravity, which articles being resistant to tipping.
- problems associated with tipping articles are significantly increased when the articles are especially lightweight, such as empty articles, that are shipped to locations for filling the articles with product.
- Assembly of article arrays is currently performed using conventional bulk palletizers.
- Most conventional bulk palletizers build the complete article array or bulk array or article layer and then move or “sweep” the completed array layer or bulk array into position onto the pallet.
- Palletizing robots are also used, but most palletizing robots also move the completed article layer or bulk array onto the pallet.
- the palletizing robots construct an article array by placing individual rows of articles to form the array.
- the conventional palletizer constructions are difficult to be quickly and cost effectively re-configured to accommodate different article designs or array patterns.
- articles 12 having non-uniform geometries pose additional challenges, as they are prone to tipping, even when supported along the collective periphery of the article array or layer.
- empty articles having non-uniform geometry are typically transported to packaging facilities using two techniques.
- a first technique the articles are loosely loaded en masse into a container having a liner. This technique results in a random, inconsistent and inefficient arrangement of the articles in the container.
- a rectangular container to be filled with articles is disposed at an angle from a horizontal plane.
- the container either manually or with aid of a robotic arm, is loaded with rows of articles that are alternatively inverted, providing a consistent, improved container arrangement.
- both approaches have the disadvantage of having to dispose of both the container and the container liner.
- the present invention relates to a method for packaging articles.
- the steps include arranging a plurality of articles having a substantially non-uniform geometry within a first collection area and transporting the plurality of articles from the first collection area to a consolidation area for constructing an article layer.
- the method further includes laterally supporting the periphery of the plurality of articles arranged within the consolidation area to substantially prevent tipping of the plurality of articles and arranging a subsequent plurality of articles within the first collection area.
- the method further includes transporting the subsequent plurality of articles from the first collection area to the consolidation area adjacent the plurality of arranged articles, the periphery of the plurality of arranged articles being continuously laterally supported while the subsequent plurality of articles is being arranged.
- the orientation of the subsequent plurality of articles is different than the orientation of the plurality of arranged articles.
- the periphery of the plurality of arranged and subsequently arranged articles is laterally supported.
- the method further includes repeating the arranging and transporting steps for subsequent plurality of articles until the article layer is constructed and substantially enclosing the article layer in a layer of resilient material substantially maintaining the arrangement of the article layer.
- the present invention further relates to a system for packaging articles including a first collection area for receiving and arranging a plurality of articles having a substantially non-uniform geometry.
- a transport device is included and a consolidation area for constructing an article layer, each article layer constructed from the plurality of arranged articles transported from the first collection area by the transport device.
- the consolidation area includes a stabilizer providing substantially continuous lateral support along the periphery of arranged articles of the article layer being constructed to substantially prevent tipping of the plurality of arranged articles.
- a portion of the arranged articles transported by the transport device is oriented differently from the other arranged articles.
- An advantage of the present invention is that article layers of articles having non-uniform geometry are substantially prevented from tipping.
- a further advantage of the present invention is that article layers of articles having non-uniform geometry can be enclosed in a resilient layer of material, not requiring a container.
- a yet further advantage of the present invention is that the arrangement of the articles of an article layer is substantially similar to the arrangement of an enclosed article layer.
- a still further advantage of the present invention is that enclosed article layers of articles having non-uniform geometry can be arranged on a pallet.
- the present invention encloses article layers of articles having non-uniform geometry without requiring a container.
- FIG. 1 is an elevation view of articles having non-uniform geometries for use with the present disclosure.
- FIG. 2 is a schematic of an embodiment of an article packaging system of the present disclosure.
- FIG. 3 is a partial cutaway of an elevation view of an embodiment of a consolidation area of the present disclosure.
- FIGS. 4-6 show sequential steps in the operation of an embodiment of article layer construction of FIG. 3 having a lateral support system of the present disclosure.
- FIG. 7 is a perspective view of the consolidation area of FIG. 3 containing a row of articles of the present disclosure.
- FIGS. 8-14 show sequential steps in the operation of an embodiment of article layer construction of FIG. 3 having a lateral support system of the present disclosure.
- FIG. 15 is an elevation view of an embodiment of the juncture of the consolidation/bagging areas of the present disclosure.
- FIGS. 16-18 show sequential steps in the operation of the consolidation/bagging areas of the present disclosure.
- FIG. 19 is a cross-section taken along line 19 - 19 of FIG. 2 of an embodiment of a bagging area of the present disclosure.
- FIGS. 20-23 show sequential steps in the operation of the lateral support system of an embodiment of the bagging area of FIG. 19 of the present disclosure.
- FIG. 24 shows a perspective view of an embodiment of a bagging area and unloading area of the present disclosure.
- the present disclosure includes a system 10 and method for packaging articles 12 ( FIG. 1 ) having a substantially non-uniform geometry as shown in FIG. 2 .
- article packaging system 10 articles 12 are guided along a conveyor 14 to a collection area 16 .
- the articles 12 are then transported by a robot, e.g., robotic arm 28 ( FIG. 3 ) from collection area 16 to a consolidation area 18 that includes a stabilizer 32 ( FIG. 3 ) for providing lateral support for articles 12 supplied to the consolidation area 18 .
- Robotic arm 28 further transports articles 12 from collection area 16 to consolidation area 18 to construct an article layer 50 ( FIG. 15 ).
- a portion of the articles 12 of article layer 50 are oriented differently than other portions of article layer 50 , as will be discussed in further detail, resulting in increased volumnar density of the article layer.
- the article layer 50 is moved from consolidation area 18 to bagging area 20 to substantially enclose the article layer in a layer of resilient material, such as plastic wrap (see FIG. 23 ).
- resilient material layers 52 , 54 are applied to corresponding portions of opposite ends of article layer 50 to form a bagged or enclosed article array or layer 22 .
- the article array or layer 22 is moved to an unloading area 21 and moved by a stacking device 24 onto a pallet 26 .
- the term “substantially non-uniform geometry” is intended to refer to articles, such as articles 12 in FIG. 1 , which are not configured to form an article layer of stable construction when the articles are substantially oriented in a like manner.
- articles 12 have a tapered profile in one direction, i.e., having a narrow dimension along a base of the article, increasing to a larger dimension adjacent to a top of the article.
- this difference in dimensions between the base and top of the article renders an article layer constructed with similarly oriented articles 12 unstable, e.g., prone to tipping, even when the article layer is laterally supported along its collective periphery.
- the term “substantially non-uniform geometry” includes article constructions that are asymmetrical as well as symmetrical about a reference axis or plane.
- an end effector 30 such as associated with a pneumatic source (not shown) of robotic arm 28 , engages article 12 disposed on collection area 16 ( FIG. 2 ) along conveyor 14 .
- robotic arm 28 includes a plurality of end effectors 30 , each engaging a corresponding article 12 forming article row 44 that is disposed on collection area 16 .
- Opposing supports 15 provide lateral support for articles 12 directed along conveyor 14 .
- Adjacent to collection area 16 is a stabilizer 32 that includes a retaining tray 34 having opposed sides 36 , 38 as more fully shown in FIG. 7 ( FIGS. 3-6 and 8 - 14 do not show side 36 of tray 34 for clarity).
- stabilizer 32 further includes a stabilizer bar 40 and a backstop 42 which are each independently movable with respect to tray 34 . That is, stabilizer bar 40 moves toward/away from backstop 42 , and backstop 42 rotates (see FIG. 16 ) sufficiently out of the way to permit tray 34 , including stabilizer bar 40 to move from consolidation area 18 to bagging area 20 .
- a supporting region 41 is defined by stabilizer bar 40 , backstop 42 and sides 36 , 38 of tray 34 to provide peripheral lateral support for article row 44 placed in the supporting region 41 .
- each article 12 of article row 44 which is engaged to a corresponding end effector 30 , is raised from collection area 16 ( FIG. 2 ) and guided by robotic arm 28 to supporting region 41 .
- FIG. 7 shows article row 44 laterally secured in supporting region 41 .
- a second article row 46 is added toward construction of an article layer 50 (e.g., FIG. 15 ).
- alternating article rows are engaged differently at collection area 16 . That is, each article 12 of article row 44 ( FIG. 3 ) is engaged from an upper portion of a side of article 12 facing away from consolidation area 18 .
- each article 12 of article row 46 ( FIG. 8 ) is engaged from a lower portion of a side of article 12 facing toward consolidation area 18 .
- support 15 contains discontinuities, such as slots, permitting end effectors 30 to engage corresponding articles 12 of article row 46 , and further permitting robotic arm 28 to raise each article 12 of article row 46 from collection area 16 .
- robotic arm 28 changes the orientation of article row 46 as robotic arm 28 is directed to move from collection area 16 toward supporting region 41 . That is, robotic arm 28 inverts article row 46 after article row 46 is raised from collection area 16 and prior to article row 46 being installed in supporting region 41 . As shown in FIG. 11 , a lower portion of article row 46 is brought into close proximity, or in physical contact with an upper portion of article row 44 that is already disposed and laterally supported in supporting region 41 .
- article row 46 By virtue of the close proximity/physical contact provided by article row 46 , continuous peripheral lateral support is provided to article row 44 , as substantially simultaneously with the lower portion of article row 46 being brought into close proximity, or in physical contact with an upper portion of article row 44 , stabilizer bar 40 moves toward collection area 16 . As shown in FIG. 12 , inverted row 46 , remaining in close proximity to article row 44 , is directed into supporting region 41 . It is to be understood that the other portions of the periphery of article rows 44 , 46 not associated with stabilizer bar 40 , i.e., in contact or close proximity with stabilizer bar 40 , are supported by the remaining portions of stabilizer 32 , i.e., opposed sides 36 , 38 of retaining tray 34 and backstop 42 .
- article layer 50 has an increased volumnar density.
- the resulting article layer 50 is less apt to shift position, and is thus, more stable for transport.
- alternating article rows are inverted in one embodiment, to construct article layer 50 , it may be desirable to use a different orientation sequence. That is, several adjacent article rows may have the same orientation, inverted or non-inverted.
- the term “different orientation” is not limited to mean inverted versus non-inverted, as there may be other possible orientations, depending upon the geometry of the article that is to be packaged.
- the completed article layer 50 is then directed from consolidation area 18 to bagging area 20 in order to apply a layer of material over the article layer, surrounding the article layer, ultimately resulting in a bagged array or enclosed article layer 22 ( FIG. 24 ).
- bagged array, enclosed array, substantially enclosed array, enclosed layer or combination thereof may be used interchangeably.
- material layers 52 and 54 provided by separate material layer sources (not shown) are used to substantially enclose article layer 50 .
- Material layer 52 is applied to the upper portion (e.g., half) of article layer 50
- material layer 54 is applied to the lower portion (e.g., half) of article layer 50 .
- Material 52 and material 54 form a junction 84 ( FIG. 15 ) as a result of the bagging operation of the previous article layer.
- stabilizer 32 is directed into bagging area 20 .
- junction 84 is disposed between backstop 42 and article layer 50 .
- backstop 42 rotates out of the way, permitting the stabilizer to pass over the backstop.
- material layer 52 is applied over the upper portion of article layer 50 and material layer 54 is applied over the lower surface of the retaining tray 34 , corresponding to the lower portion of the article layer, with material layers 50 , 54 substantially forming a tube of material.
- junction 84 of the material layers 52 , 54 continue to provide lateral support to the end of article layer 50 facing away from consolidation area 18 , formerly supported by backstop 42 . Therefore, lateral support along the outer periphery of article layer 50 is maintained as the article layer passes from consolidation area 18 to bagging area 20 .
- tensioning devices 56 , 58 are employed to controllably feed respective material layers 52 , 54 over article layer 50 with a sufficient, but not excessive amount of tension or tensile force.
- Material layer 52 from the material layer source engages a number of respective rollers 63 , 64 prior to terminating at junction 84 .
- material layer 54 from the material layer source engages a number of respective rollers 65 , 66 prior to terminating at junction 84 .
- Tensioning device 56 includes a ramp 60 supporting an axle 68 , which engages a loop 72 of material formed from material layer 52 disposed between rollers 64 .
- tensioning device 58 includes a ramp 62 supporting an axle 70 which engages a loop 74 of material formed from material layer 54 disposed between rollers 66 .
- loops 72 , 74 are sufficiently sized to dispense a corresponding length of respective material layers 52 , 54 to enclose the lengthwise periphery of article layer 50 (e.g., FIG. 17 ).
- the size of each loop 72 , 74 of respective material layer 52 , 54 is reduced, as the material layers 52 , 54 are being applied to the upper and lower portions of the article layer 50 sufficient to surround the article layer.
- the geometry, i.e., length and slope, of the ramps 60 , 62 are determined by a number of factors, including the number and locations of respective rollers 63 , 64 , 65 , 66 for a given weight of axle 68 , 70 , as well as available room in the article packaging system.
- a predetermined length of material layers 52 , 54 is applied to the respective upper and lower portions of article layer 50 from corresponding loops 72 , 74 of material layers 52 , 54 .
- FIGS. 15 and 16 show loops 72 , 74 both prior to ( FIG.
- Tensioning devices 56 , 58 provide a tensile force that is substantially evenly distributed along the lengths of respective axles 68 , 70 for each of material layer 52 , 54 . This tensile force permits even application of material layer 52 , 54 over article layer 50 , and is generated by the force of gravity associated with urging axles 68 , 70 to roll downward along respective ramps 60 , 62 .
- retaining tray 34 is retracted to move to its original position in consolidation area 18 .
- actuator 86 urges end 90 into directed movement toward stabilizer bar 40 .
- This movement of end 90 contacts and downwardly deflects, at least along a region adjacent to end 90 , the position of material layer 52 with respect to the upper portion of article layer 50 facing consolidation area 18 .
- the downwardly deflected portion of material layer 52 in contact with article layer 50 substantially prevents tipping of article layer 50 along the resulting contact area, providing lateral support along the upper portion of article layer 50 .
- the lower portion of article layer 50 now rests directly on material layer 54 .
- End 90 has a heated element therein, that results in the formation of a new junction 84 between material layers 52 , 54 , which junction 84 acting to achieve three ends: both seal article layer 50 and sever article layer 50 from material layers 52 , 54 and forming the basis for bagged or enclosed article array or layer 22 ( FIG. 24 ), as well as establishing a new junction 84 between ends of material layers 52 , 54 opposite severed article layer 50 .
- the junction 84 formed opposite severed article layer 50 becomes the new end of the bag end used with the next article layer to be constructed, as shown in FIG. 15 .
- partially enclosed article layer 50 includes material layer 52 extending to opposed flaps 53 and material layer 54 extending to opposed flaps 55 . To enclose article layer 50 , adjacent flaps 53 , 55 are joined together.
- articles 12 of article layer 50 are maintained in position in bagging area 20 by downward extending flanges 130 (see FIG. 20 ) which are disposed in close proximity to opposed upper portions of corresponding outermost disposed rows 49 of article layer 50 .
- an anvil 108 associated with an actuator 104 extends sufficiently vertically to form a raised region in material layer 54 with respect to the lower level associated with material layer 54 disposed beneath article layer 50 , thereby acting to provide a lateral force along the lower portion of rows 49 to maintain the arrangement of the articles of article layer 50 .
- the opposed flanges 130 may be adjusted to receive both articles and the resulting article layers of different constructions, e.g., size and arrangements. As shown, rows 49 are transverse to article rows 44 , 46 , 48 ( FIG. 8 ) formed in consolidation area 18 . However, it is to be understood that flanges 130 and anvil 108 or other constructions may be used that are not transverse to article rows 44 , 46 , 48 , or even linear, if desired.
- upper flap gripper assembly 98 includes an actuator 110 that is pivotably connected to a gripper head 112 which is likewise pivotably connected to a shaft 114 . That is, in response to actuator 110 directing gripper head 112 into movement, the end of gripper head 112 also moves along an arc defined by pivoting shaft 114 .
- Gripper head 112 includes a capability to draw flap 53 into contact with gripper head 112 , such as by a pneumatic vacuum, although other techniques, such as adhesives may be used.
- actuators 110 i.e., extension of the actuators
- pivoting shafts 114 result in gripper heads 112 defining an arcuate path toward outer rows 49 of article layer 50 until gripper heads contact or are brought into close proximity with corresponding flaps 53 .
- flaps 55 extend outwardly and downward from the lower portions of rows 49 of article layer 50 .
- additional techniques such as pneumatic vacuum may be used to draw flaps 55 away from article layer 50 to more easily permit flaps 55 to be accessed.
- actuators 110 are actuated in a reverse direction than shown in FIG. 20 , i.e., retracted, resulting in gripper heads 112 , and corresponding flaps 53 secured to gripper heads 110 , moving away from rows 49 of article layer 50 .
- flaps 55 whether by force of gravity alone, or with assistance from additional features, such as pneumatic vacuum, extend outwardly and downwardly from the lower portion of article rows 49 of article layer 50 .
- motors 116 urge opposed grippers 118 to rotate, capturing corresponding flaps 53 between gripper head 112 and gripper 118 .
- motors 120 urge opposed grippers 122 to actuate, capturing corresponding flaps 55 between gripper 122 and adjacent structure, such as angle 124 .
- flaps 53 , 55 are captured, as shown in FIG. 23 , corresponding ends 106 having heated elements and anvils 108 are directed into contact by actuators 102 , 104 to form junctions 132 in the flaps of material layers 52 , 54 , similar to the formation of junctions 84 as previously discussed.
- article layer 50 is transformed into bagged article array or enclosed article layer 22 .
- article geometries may permit an arrangement in which articles in the article rows are non-aligned, i.e., staggered.
- a stacking device 24 having a gripper head 126 and grippers 128 , may transport enclosed article layer 22 onto a pallet 26 .
- stacking device 24 may locate article layers 22 to pallets 26 located at multiple positions, such as shown in FIG. 2 . It is appreciated that slip sheets and end caps (not shown) may be used to palletize the article layers 22 .
Abstract
Description
- The present invention is directed to a system and method for packaging article layers, and specifically to a system and method for packaging article layers for articles having substantially non-uniform geometries.
- When large numbers of stackable articles must be transported in large quantities to another location, especially when the article is small, the article may be packaged in a container to protect the article during shipping of the container. Alternately, to reduce the amount of handling required, the articles may be arranged in a tight grouping, or array of articles. Each array of articles can form a layer of articles that can be stacked on a pallet having a footprint which can be accommodated by freight hauling compartments, e.g., for truck, rail, sea or air vessels.
- Palletizing articles is becoming increasingly automated in manufacturing facilities, wherein articles are moved via a conveyor, which articles are manipulated by robots onto pallets. Such processing may work well if the articles are inherently stable, i.e., having a broad base footprint and low center of gravity, which articles being resistant to tipping. However, there can be difficulties associated with elongated articles having a small base footprint, as such articles are susceptible to tipping. Moreover, problems associated with tipping articles are significantly increased when the articles are especially lightweight, such as empty articles, that are shipped to locations for filling the articles with product.
- Assembly of article arrays is currently performed using conventional bulk palletizers. Most conventional bulk palletizers build the complete article array or bulk array or article layer and then move or “sweep” the completed array layer or bulk array into position onto the pallet. Palletizing robots are also used, but most palletizing robots also move the completed article layer or bulk array onto the pallet. Alternately, the palletizing robots construct an article array by placing individual rows of articles to form the array. However, the previously discussed problems associated with article tipping have not been resolved. In addition, the conventional palletizer constructions are difficult to be quickly and cost effectively re-configured to accommodate different article designs or array patterns.
- As shown in
FIG. 1 ,articles 12 having non-uniform geometries pose additional challenges, as they are prone to tipping, even when supported along the collective periphery of the article array or layer. Currently, empty articles having non-uniform geometry are typically transported to packaging facilities using two techniques. In a first technique, the articles are loosely loaded en masse into a container having a liner. This technique results in a random, inconsistent and inefficient arrangement of the articles in the container. With the other technique, a rectangular container to be filled with articles is disposed at an angle from a horizontal plane. The container, either manually or with aid of a robotic arm, is loaded with rows of articles that are alternatively inverted, providing a consistent, improved container arrangement. However, both approaches have the disadvantage of having to dispose of both the container and the container liner. - What is needed is an apparatus and method that effectively package articles having non-uniform geometries while substantially eliminating the possibility of articles tipping during packaging, that also eliminates the need for both a container and container liner for article layers and for palletized article layers.
- The present invention relates to a method for packaging articles. The steps include arranging a plurality of articles having a substantially non-uniform geometry within a first collection area and transporting the plurality of articles from the first collection area to a consolidation area for constructing an article layer. The method further includes laterally supporting the periphery of the plurality of articles arranged within the consolidation area to substantially prevent tipping of the plurality of articles and arranging a subsequent plurality of articles within the first collection area. The method further includes transporting the subsequent plurality of articles from the first collection area to the consolidation area adjacent the plurality of arranged articles, the periphery of the plurality of arranged articles being continuously laterally supported while the subsequent plurality of articles is being arranged. The orientation of the subsequent plurality of articles is different than the orientation of the plurality of arranged articles. Upon the arrangement of the subsequent plurality of articles, the periphery of the plurality of arranged and subsequently arranged articles is laterally supported. The method further includes repeating the arranging and transporting steps for subsequent plurality of articles until the article layer is constructed and substantially enclosing the article layer in a layer of resilient material substantially maintaining the arrangement of the article layer.
- The present invention further relates to a system for packaging articles including a first collection area for receiving and arranging a plurality of articles having a substantially non-uniform geometry. A transport device is included and a consolidation area for constructing an article layer, each article layer constructed from the plurality of arranged articles transported from the first collection area by the transport device. The consolidation area includes a stabilizer providing substantially continuous lateral support along the periphery of arranged articles of the article layer being constructed to substantially prevent tipping of the plurality of arranged articles. A portion of the arranged articles transported by the transport device is oriented differently from the other arranged articles.
- An advantage of the present invention is that article layers of articles having non-uniform geometry are substantially prevented from tipping.
- A further advantage of the present invention is that article layers of articles having non-uniform geometry can be enclosed in a resilient layer of material, not requiring a container.
- A yet further advantage of the present invention is that the arrangement of the articles of an article layer is substantially similar to the arrangement of an enclosed article layer.
- A still further advantage of the present invention is that enclosed article layers of articles having non-uniform geometry can be arranged on a pallet.
- The present invention encloses article layers of articles having non-uniform geometry without requiring a container.
- Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
-
FIG. 1 is an elevation view of articles having non-uniform geometries for use with the present disclosure. -
FIG. 2 is a schematic of an embodiment of an article packaging system of the present disclosure. -
FIG. 3 is a partial cutaway of an elevation view of an embodiment of a consolidation area of the present disclosure. -
FIGS. 4-6 show sequential steps in the operation of an embodiment of article layer construction ofFIG. 3 having a lateral support system of the present disclosure. -
FIG. 7 is a perspective view of the consolidation area ofFIG. 3 containing a row of articles of the present disclosure. -
FIGS. 8-14 show sequential steps in the operation of an embodiment of article layer construction ofFIG. 3 having a lateral support system of the present disclosure. -
FIG. 15 is an elevation view of an embodiment of the juncture of the consolidation/bagging areas of the present disclosure. -
FIGS. 16-18 show sequential steps in the operation of the consolidation/bagging areas of the present disclosure. -
FIG. 19 is a cross-section taken along line 19-19 ofFIG. 2 of an embodiment of a bagging area of the present disclosure. -
FIGS. 20-23 show sequential steps in the operation of the lateral support system of an embodiment of the bagging area ofFIG. 19 of the present disclosure. -
FIG. 24 shows a perspective view of an embodiment of a bagging area and unloading area of the present disclosure. - Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
- The present disclosure includes a
system 10 and method for packaging articles 12 (FIG. 1 ) having a substantially non-uniform geometry as shown inFIG. 2 . Inarticle packaging system 10,articles 12 are guided along aconveyor 14 to acollection area 16. Thearticles 12 are then transported by a robot, e.g., robotic arm 28 (FIG. 3 ) fromcollection area 16 to aconsolidation area 18 that includes a stabilizer 32 (FIG. 3 ) for providing lateral support forarticles 12 supplied to theconsolidation area 18.Robotic arm 28 further transportsarticles 12 fromcollection area 16 toconsolidation area 18 to construct an article layer 50 (FIG. 15 ). A portion of thearticles 12 ofarticle layer 50 are oriented differently than other portions ofarticle layer 50, as will be discussed in further detail, resulting in increased volumnar density of the article layer. Oncearticle layer 50 has been constructed, thearticle layer 50 is moved fromconsolidation area 18 to baggingarea 20 to substantially enclose the article layer in a layer of resilient material, such as plastic wrap (seeFIG. 23 ). In one embodiment,resilient material layers article layer 50 to form a bagged or enclosed article array orlayer 22. After article array orlayer 22 is formed inbagging area 20, the article array orlayer 22 is moved to anunloading area 21 and moved by astacking device 24 onto apallet 26. - As used herein, the term “substantially non-uniform geometry” is intended to refer to articles, such as
articles 12 inFIG. 1 , which are not configured to form an article layer of stable construction when the articles are substantially oriented in a like manner. In one embodiment,articles 12 have a tapered profile in one direction, i.e., having a narrow dimension along a base of the article, increasing to a larger dimension adjacent to a top of the article. As can be appreciated by those skilled in the art, and inspection ofFIG. 1 , this difference in dimensions between the base and top of the article renders an article layer constructed with similarly orientedarticles 12 unstable, e.g., prone to tipping, even when the article layer is laterally supported along its collective periphery. In addition, the term “substantially non-uniform geometry” includes article constructions that are asymmetrical as well as symmetrical about a reference axis or plane. - As shown in
FIGS. 3-7 , which includes a partial cutaway ofstabilizer 32, anend effector 30, such as associated with a pneumatic source (not shown) ofrobotic arm 28, engagesarticle 12 disposed on collection area 16 (FIG. 2 ) alongconveyor 14. In one embodiment,robotic arm 28 includes a plurality ofend effectors 30, each engaging acorresponding article 12 formingarticle row 44 that is disposed oncollection area 16. Opposing supports 15 provide lateral support forarticles 12 directed alongconveyor 14. Adjacent tocollection area 16 is astabilizer 32 that includes a retainingtray 34 having opposedsides FIG. 7 (FIGS. 3-6 and 8-14 do not showside 36 oftray 34 for clarity). In one embodiment,stabilizer 32 further includes astabilizer bar 40 and abackstop 42 which are each independently movable with respect totray 34. That is,stabilizer bar 40 moves toward/away frombackstop 42, and backstop 42 rotates (seeFIG. 16 ) sufficiently out of the way to permittray 34, includingstabilizer bar 40 to move fromconsolidation area 18 to baggingarea 20. A supportingregion 41 is defined bystabilizer bar 40, backstop 42 andsides tray 34 to provide peripheral lateral support forarticle row 44 placed in the supportingregion 41. - Hereafter, although the Figures show elevation views that may appear as a single article, it is to be understood that the same views may also apply to article rows. Thus, as a general matter, the terms article and article rows may be used interchangeably.
- As shown in
FIGS. 4-6 , eacharticle 12 ofarticle row 44, which is engaged to acorresponding end effector 30, is raised from collection area 16 (FIG. 2 ) and guided byrobotic arm 28 to supportingregion 41.FIG. 7 showsarticle row 44 laterally secured in supportingregion 41. - As shown in
FIGS. 8-12 , asecond article row 46 is added toward construction of an article layer 50 (e.g.,FIG. 15 ). In one embodiment, alternating article rows are engaged differently atcollection area 16. That is, eacharticle 12 of article row 44 (FIG. 3 ) is engaged from an upper portion of a side ofarticle 12 facing away fromconsolidation area 18. In contrast, as shown inFIG. 8 , eacharticle 12 of article row 46 (FIG. 8 ) is engaged from a lower portion of a side ofarticle 12 facing towardconsolidation area 18. Although not specifically shown,support 15 contains discontinuities, such as slots, permittingend effectors 30 to engage correspondingarticles 12 ofarticle row 46, and further permittingrobotic arm 28 to raise eacharticle 12 ofarticle row 46 fromcollection area 16. - As further shown in
FIGS. 9-10 ,robotic arm 28 changes the orientation ofarticle row 46 asrobotic arm 28 is directed to move fromcollection area 16 toward supportingregion 41. That is,robotic arm 28inverts article row 46 afterarticle row 46 is raised fromcollection area 16 and prior toarticle row 46 being installed in supportingregion 41. As shown inFIG. 11 , a lower portion ofarticle row 46 is brought into close proximity, or in physical contact with an upper portion ofarticle row 44 that is already disposed and laterally supported in supportingregion 41. By virtue of the close proximity/physical contact provided byarticle row 46, continuous peripheral lateral support is provided toarticle row 44, as substantially simultaneously with the lower portion ofarticle row 46 being brought into close proximity, or in physical contact with an upper portion ofarticle row 44,stabilizer bar 40 moves towardcollection area 16. As shown inFIG. 12 ,inverted row 46, remaining in close proximity toarticle row 44, is directed into supportingregion 41. It is to be understood that the other portions of the periphery ofarticle rows stabilizer bar 40, i.e., in contact or close proximity withstabilizer bar 40, are supported by the remaining portions ofstabilizer 32, i.e., opposedsides tray 34 andbackstop 42. - Once
article row 46 is fully installed in supportingregion 41 so thatarticle rows region 41,stabilizer bar 40 moves towardarticle row 46 untilstabilizer bar 40 is in close proximity/physical contact witharticle row 46, providing lateral support toarticle row 46, as shown inFIG. 13 . Afterstabilizer bar 40 is disposed in close proximity/physical contact witharticle row 46,end effectors 30 disengage fromarticle row 46, androbotic arm 28 returns adjacent tocollection area 16. In the embodiment as shown, the sequence ofFIGS. 3-6 is repeated, resulting in the installation ofarticle row 48 in supportingregion 41 as shown inFIG. 14 . Upon the completion of the installation of a sufficient number of article rows, a full article row or article layer 50 (FIG. 15 ) is completed. - It is to be understood that by virtue of orienting a portion of the article rows differently than the remaining article rows of an article layer, the amount of volume displaced by the resulting article layer, i.e., article layer 50 (
FIG. 15 ) as shown, is significantly less than an article layer in which the article rows have the same orientation (seeFIG. 1 ). Stated differently,article layer 50 has an increased volumnar density. In addition to the increased volumnar density, by virtue of the enhanced degree of proximity between article rows, the resultingarticle layer 50 is less apt to shift position, and is thus, more stable for transport. - It is to be understood that while alternating article rows are inverted in one embodiment, to construct
article layer 50, it may be desirable to use a different orientation sequence. That is, several adjacent article rows may have the same orientation, inverted or non-inverted. In addition, the term “different orientation” is not limited to mean inverted versus non-inverted, as there may be other possible orientations, depending upon the geometry of the article that is to be packaged. - As shown in
FIGS. 15-18 , the completedarticle layer 50 is then directed fromconsolidation area 18 to baggingarea 20 in order to apply a layer of material over the article layer, surrounding the article layer, ultimately resulting in a bagged array or enclosed article layer 22 (FIG. 24 ). The terms bagged array, enclosed array, substantially enclosed array, enclosed layer or combination thereof may be used interchangeably. As further shown, material layers 52 and 54 provided by separate material layer sources (not shown) are used to substantially enclosearticle layer 50.Material layer 52 is applied to the upper portion (e.g., half) ofarticle layer 50, andmaterial layer 54 is applied to the lower portion (e.g., half) ofarticle layer 50.Material 52 andmaterial 54 form a junction 84 (FIG. 15 ) as a result of the bagging operation of the previous article layer. - As shown in
FIG. 16 ,stabilizer 32, is directed into baggingarea 20. In one embodiment,junction 84 is disposed betweenbackstop 42 andarticle layer 50. By virtue of this arrangement, in response to movement ofstabilizer 32 toward baggingarea 20, backstop 42 rotates out of the way, permitting the stabilizer to pass over the backstop. Also in response to movement ofstabilizer 32 toward baggingarea 20,material layer 52 is applied over the upper portion ofarticle layer 50 andmaterial layer 54 is applied over the lower surface of the retainingtray 34, corresponding to the lower portion of the article layer, withmaterial layers material layers junction 84 of the material layers 52, 54 continue to provide lateral support to the end ofarticle layer 50 facing away fromconsolidation area 18, formerly supported bybackstop 42. Therefore, lateral support along the outer periphery ofarticle layer 50 is maintained as the article layer passes fromconsolidation area 18 to baggingarea 20. - Referring back to
FIG. 15 ,tensioning devices 56, 58 are employed to controllably feed respective material layers 52, 54 overarticle layer 50 with a sufficient, but not excessive amount of tension or tensile force.Material layer 52 from the material layer source (not shown) engages a number ofrespective rollers junction 84. Similarly,material layer 54 from the material layer source (not shown) engages a number ofrespective rollers junction 84. Tensioning device 56 includes aramp 60 supporting anaxle 68, which engages aloop 72 of material formed frommaterial layer 52 disposed betweenrollers 64. In a like manner, tensioningdevice 58 includes aramp 62 supporting anaxle 70 which engages aloop 74 of material formed frommaterial layer 54 disposed betweenrollers 66. In one embodiment,loops FIG. 17 ). In operation, in response tostabilizer 32 being directed toward baggingarea 20, the size of eachloop respective material layer article layer 50 sufficient to surround the article layer. - The geometry, i.e., length and slope, of the
ramps respective rollers axle stabilizer 32 being directed fromconsolidation area 18 to baggingarea 20, a predetermined length of material layers 52, 54 is applied to the respective upper and lower portions ofarticle layer 50 from correspondingloops FIGS. 15 and 16 show loops FIG. 15 ) and after material layers 52, 54 have been provided to enclosearticle layer 50, as evidenced by movement ofaxle 68 towardrollers 64 and movement ofaxle 70 toward rollers 66 (seeFIG. 16 ).Tensioning devices 56, 58 provide a tensile force that is substantially evenly distributed along the lengths ofrespective axles material layer material layer article layer 50, and is generated by the force of gravity associated with urgingaxles respective ramps - After the combined
stabilizer 32 andarticle layer 50 have been initially directed into bagging area 20 (FIG. 16 ), as shown inFIG. 17 , retainingtray 34 is retracted to move to its original position inconsolidation area 18. However, just prior to or substantially simultaneously with the retraction of retainingtray 34,actuator 86 urges end 90 into directed movement towardstabilizer bar 40. This movement ofend 90 contacts and downwardly deflects, at least along a region adjacent to end 90, the position ofmaterial layer 52 with respect to the upper portion ofarticle layer 50 facingconsolidation area 18. The downwardly deflected portion ofmaterial layer 52 in contact witharticle layer 50 substantially prevents tipping ofarticle layer 50 along the resulting contact area, providing lateral support along the upper portion ofarticle layer 50. As a result of the retraction of retainingtray 34, the lower portion ofarticle layer 50 now rests directly onmaterial layer 54. - As shown in
FIG. 18 , once retainingtray 34 has been retracted,stabilizer bar 40 is then retracted to move to its original position inconsolidation area 18. As a result of the downwardly deflected portion ofmaterial layer 52 in response to the previously described downward movement ofend 90, material layers 52, 54 joined alongjunction 84 facingbagging area 20 substantially enclosearticle layer 50 sufficient to provide lateral support along the periphery ofmaterial layers anvil 92 are directed into contact with each other byrespective actuators End 90 has a heated element therein, that results in the formation of anew junction 84 between material layers 52, 54, whichjunction 84 acting to achieve three ends: bothseal article layer 50 and severarticle layer 50 frommaterial layers FIG. 24 ), as well as establishing anew junction 84 between ends ofmaterial layers article layer 50. Thejunction 84 formed opposite severedarticle layer 50 becomes the new end of the bag end used with the next article layer to be constructed, as shown inFIG. 15 . - Once the tube of material
enclosing article layer 50 is formed, i.e., the ends ofmaterial layers junction 84 as discussed above,material loops material loops FIG. 15 ) directsdrive roller 76 into rotation to drawmaterial layer 52 from the material layer source to enlargeloop 72 associated withaxle 68. Asloop 72 is enlarged,axle 68 proceeds downwardly alongramp 60 toward aproximity switch 94 untilaxle 68 actuatesproximity switch 94. Upon actuation ofproximity switch 94, operation ofmotor 80 is discontinued. Similarly, motor 82 (FIG. 15 ) directsdrive roller 78 into rotation to drawmaterial layer 54 from the material layer source to enlargeloop 74 associated withaxle 70. Asloop 74 is enlarged,axle 70 proceeds downwardly alongramp 62 toward aproximity switch 96 untilaxle 70 actuatesproximity switch 96. Upon actuation ofproximity switch 96, operation ofmotor 82 is discontinued. In other words,motors respective loops - In addition, once the tube of material
enclosing article layer 50 is formed, the ends of tube material disposed transverse tojunctions 84 must be closed to form bagged article array or enclosed layer 22 (FIG. 24 ) to ensure the articles inarticle layer 50 remain substantially in position, i.e., substantially maintain the arrangement of articles ofarticle layer 50. As shown inFIGS. 19-23 , which is a cross-section of baggingarea 20 taken along line 19-19 ofFIG. 2 , partiallyenclosed article layer 50 includesmaterial layer 52 extending toopposed flaps 53 andmaterial layer 54 extending to opposed flaps 55. To enclosearticle layer 50,adjacent flaps articles 12 ofarticle layer 50 are maintained in position in baggingarea 20 by downward extending flanges 130 (seeFIG. 20 ) which are disposed in close proximity to opposed upper portions of corresponding outermostdisposed rows 49 ofarticle layer 50. In addition, if required, ananvil 108 associated with anactuator 104 extends sufficiently vertically to form a raised region inmaterial layer 54 with respect to the lower level associated withmaterial layer 54 disposed beneatharticle layer 50, thereby acting to provide a lateral force along the lower portion ofrows 49 to maintain the arrangement of the articles ofarticle layer 50. It is appreciated that theopposed flanges 130 may be adjusted to receive both articles and the resulting article layers of different constructions, e.g., size and arrangements. As shown,rows 49 are transverse toarticle rows FIG. 8 ) formed inconsolidation area 18. However, it is to be understood thatflanges 130 andanvil 108 or other constructions may be used that are not transverse toarticle rows - As further shown in
FIG. 19 , opposed upperflap gripper assemblies 98 are configured to grip eachflap 53, and opposed lowerflap gripper assemblies 100 are configured to grip eachflap 55. In one embodiment, upperflap gripper assembly 98 includes anactuator 110 that is pivotably connected to agripper head 112 which is likewise pivotably connected to ashaft 114. That is, in response toactuator 110 directinggripper head 112 into movement, the end ofgripper head 112 also moves along an arc defined by pivotingshaft 114.Gripper head 112 includes a capability to drawflap 53 into contact withgripper head 112, such as by a pneumatic vacuum, although other techniques, such as adhesives may be used. - As shown in
FIG. 20 , movement ofactuators 110, i.e., extension of the actuators, in combination with pivotingshafts 114 result in gripper heads 112 defining an arcuate path towardouter rows 49 ofarticle layer 50 until gripper heads contact or are brought into close proximity withcorresponding flaps 53. By force of gravity, flaps 55 extend outwardly and downward from the lower portions ofrows 49 ofarticle layer 50. In an alternate embodiment, additional techniques, such as pneumatic vacuum may be used to drawflaps 55 away fromarticle layer 50 to more easily permit flaps 55 to be accessed. - As shown in
FIG. 21 , once gripper heads 112 have been brought into contact or at least in close proximity toflaps 53,actuators 110 are actuated in a reverse direction than shown inFIG. 20 , i.e., retracted, resulting in gripper heads 112, and correspondingflaps 53 secured to gripper heads 110, moving away fromrows 49 ofarticle layer 50. In addition, flaps 55, whether by force of gravity alone, or with assistance from additional features, such as pneumatic vacuum, extend outwardly and downwardly from the lower portion ofarticle rows 49 ofarticle layer 50. - As shown in
FIG. 22 , onceactuators 110 are sufficiently retracted,motors 116 urge opposedgrippers 118 to rotate, capturing correspondingflaps 53 betweengripper head 112 andgripper 118. Similarly,motors 120 urge opposedgrippers 122 to actuate, capturing correspondingflaps 55 betweengripper 122 and adjacent structure, such asangle 124. Once flaps 53, 55 are captured, as shown inFIG. 23 , corresponding ends 106 having heated elements andanvils 108 are directed into contact byactuators junctions 132 in the flaps ofmaterial layers junctions 84 as previously discussed. Upon formation ofjunctions 132,article layer 50 is transformed into bagged article array orenclosed article layer 22. - It is appreciated that upon the
article layer 50 moving fromconsolidation area 18 to baggingarea 20, oncestabilizer 32 returns toconsolidation area 18, many of the operations discussed herein may be performed simultaneously to optimize performance of the article packaging system. - It is also to be understood that while articles of the article layer, as shown in one embodiment, are arranged in aligned rows that are substantially parallel to each other and are also aligned in a transverse direction, article geometries may permit an arrangement in which articles in the article rows are non-aligned, i.e., staggered.
- As shown in
FIG. 24 , once enclosedarticle layer 22 is formed, it is moved from baggingarea 20 to unloadingarea 21. A stackingdevice 24, having agripper head 126 andgrippers 128, may transportenclosed article layer 22 onto apallet 26. In one embodiment, stackingdevice 24 may locate article layers 22 topallets 26 located at multiple positions, such as shown inFIG. 2 . It is appreciated that slip sheets and end caps (not shown) may be used to palletize the article layers 22. - While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims (23)
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US11/849,619 US7506490B1 (en) | 2007-09-04 | 2007-09-04 | System and method for packaging article layers |
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US20140026523A1 (en) * | 2012-07-27 | 2014-01-30 | Morrison Container Handling Solutions, Inc. | Packaging system and method |
US20210221628A1 (en) * | 2017-10-31 | 2021-07-22 | Dyco, Inc. | Method for forming an article array |
WO2021239625A1 (en) * | 2020-05-26 | 2021-12-02 | Focke & Co. (Gmbh & Co. Kg) | Method and device for strapping a group of packages |
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DE102010049588A1 (en) * | 2010-10-26 | 2012-04-26 | Multivac Sepp Haggenmüller Gmbh & Co. Kg | Shell sealing machine and method of operating such a tray sealing machine |
US10894621B2 (en) * | 2014-07-17 | 2021-01-19 | Pacwell Ip Pty Ltd | Carton packing apparatus |
US10144596B2 (en) * | 2015-05-26 | 2018-12-04 | Dyco, Inc. | System and method for forming and moving an article array |
US9586769B2 (en) | 2015-05-26 | 2017-03-07 | Dyco, Inc. | System and method for forming and moving an article array |
US10589943B1 (en) * | 2019-06-24 | 2020-03-17 | Dyco, Inc. | System and method for forming and moving an article array |
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