Abstract:
A method of constructing a palletizer cell by providing square platform bases which are assembled into an array in abutment with each other, each platform base mounting a respective component of palletizing equipment, such as a robot, one or more conveyors, a slip sheet bin, a discharge module, etc. with one platform base anchored to the factory floor and the rest attached to one or another of the platform bases to form the array of platform bases thereby properly locating the various equipment with each other by the fitting together of the platform bases. Safety fencing sections are mounted atop one or more outer sides to substantially enclose the space within the palletizer cell. Each platform base is formed with side openings which may be engaged with the tines of a fork lift.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. provisional application No. 61/444,507 filed on Feb. 18, 2011, incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention concerns robotic palletizing cells, in which items are stacked by robots. Palletizing has in the past traditionally mostly been done by dedicated automation equipment. 
         [0003]    In more recent years, robotic palletizing in which a robot carries out stacking of product has become more common for some applications, due to increased flexibility in layout, configuration, and pallet pattern creation and in running multiple lines. 
         [0004]    Robotic palletizing involves custom designing the layout of the various pieces of equipment, such as the robot, conveyors, pallet stacks, etc., and then locating each piece of the equipment on the factory floor in the proper position and separately anchoring each piece of equipment to the factory floor, and running wires in the field to reach each electrically operated device. 
         [0005]    Each piece of equipment also needs to be custom engineered and installed with the appropriate positional relationship to each other. 
         [0006]    The result of this approach is that the time required to design, build and install a palletizer cell is considerable, and the cost relatively high. 
         [0007]    While some attempts have been made to build standardized elements of the equipment needed, these have been lacking in their ability to be adapted to particular applications and to be configured differently for those applications, and in any event each element needed to be set up in the field in an appropriate position. 
         [0008]    It is an object of the present invention to provide modular equipment and a method for creating pelletizing cells which make, designing, building and installing such cells much quicker and cheaper than previously possible by reducing the need for independently locating each item of equipment in the installation process. 
       SUMMARY OF THE INVENTION 
       [0009]    The above recited object as well as other objects which will be understood by those skilled in the art upon reading the following specification and claims are achieved by providing a plurality of standard modules which each incorporate a rectangular, preferably square, platform base of a uniform overall size and adapted to be held in contact with each other, as by attached connector plates, with at least one platform base anchored to the factory floor. 
         [0010]    The platform bases are thereby formed into a fit together array of platform bases, thereby locating various palletizing equipment mounted to the platform bases relative to each other by simply assembling the platforms bases into an interfit array of modules on the factory floor. 
         [0011]    Preferably, a robot module has its associated platform base anchored to the floor as by lag bolting projecting angled channel pieces located at spaced locations about its perimeter to the floor. 
         [0012]    The remaining platform bases are fit together to form an array, with one or more platform bases held in contact with the perimeter of the robot module platform base and also to other of the platform bases which are held in contact with other platform bases. The array may be held together as by installing connector pieces overlapped with abutting portions of each platform base. Thus, the other platform bases may be left unanchored and only indirectly anchored to the floor by the connection to the anchored platform base; or, additional platform bases can also be anchored to the floor if desired. The platform bases of the robot module and the other modules and the equipment items mounted thereto are held in a predetermined spatial relationship by simply being together in the array. 
         [0013]    The platform bases of each of the modules may comprise a thick steel plate supported above floor level as by having inwardly facing sections of channel or square tubing welded beneath the edges of the top plate on each side thereof. 
         [0014]    Each platform base preferably has fork lift openings defined by gaps between the channel or square tube sections on each side. The projecting angled channel pieces of the anchored platform base may be received in the fork lift openings of the other the platform bases to be interfit therewith to allow side to side abutment of other platform bases therewith notwithstanding the presence of the projecting anchoring pieces. 
         [0015]    The various types of modules which can be provided include a single or a double product feed conveyor, a slip sheet module, a pallet module, a discharge module with a chain conveyor for discharging loaded conveyors, each mounted to an associated platform base. 
         [0016]    The platform bases may be in two different forms, a solid square forming a part of the above listed modules, and a platform base for a “build” module formed with a large opening extending into one side to create a U-shape while maintaining the overall square shape and size of the first form of platform base for allowing loading of a pallet disposed directly on the plant floor confined and located within the opening or for receiving a stack of pallets to be accessed by a robot. 
         [0017]    Tapped hole patterns are provided machined into the upper surface of the top plate of each platform base for attaching connector pieces and also to allow mounting of uprights for supporting safety screens along one or more of the sides of each platform base to limit access to the interior space of the palletizer cell. 
         [0018]    The modules can be arranged in many different configurations by assembling platform bases in various the positions within the array so as to minimize the engineering development necessary by the use of standardized components, allowing them to be provided at a lower cost. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0019]      FIG. 1  is a pictorial view of a palletizer cell constructed according to the present invention. 
           [0020]      FIG. 2  is a pictorial view of a second configuration of a palletizer cell constructed according to the present invention. 
           [0021]      FIG. 3  is a pictorial view of a standard platform base, several of which being incorporated in the palletizer arrangements shown in  FIGS. 1 and 2 . 
           [0022]      FIG. 3A  is a plan view of a platform base having a slip sheet bin installed thereon showing the tapped hole patterns and a connector plate fixed thereto to connect to an adjacent platform base shown. 
           [0023]      FIG. 3B  is an enlarged broken away plan view of a blank platform base connected to a platform base having a slip sheet bin mounted thereon, showing the tapped hole patterns and additional connector plates and safety fence uprights and bases. 
           [0024]      FIG. 4  is a pictorial view of a single pick module incorporated in the palletizer shown in  FIG. 2 . 
           [0025]      FIG. 5  is a pictorial view of a build module also included in each of the palletizer cells shown in  FIGS. 1 and 2 . 
           [0026]      FIG. 6  is a pictorial view of a slip sheet module incorporated in the palletizer cells shown in  FIG. 2 . 
           [0027]      FIG. 7  is a pictorial view of a double pick module incorporated in the palletizer cell of  FIG. 1 . 
           [0028]      FIG. 8  is a plan view of a platform base configuration adapted to be anchored to the floor and having a robot mounted thereon. 
           [0029]      FIG. 9  is a pictorial view of a discharge module. 
           [0030]      FIG. 10  is a pictorial view of a build module with a stack of pallets in position and with a safety light curtain activated in front of the pallet stack. 
       
    
    
     DETAILED DESCRIPTION 
       [0031]    In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of 35 USC 112, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims. 
         [0032]    Referring to the drawings, and particularly  FIG. 1 , a palletizer cell  10  is shown, constructed using components according to the present invention. This includes a plurality of rectangular, preferably square, platform bases of two different types, i.e., four solid square platform bases  12 A,  12 B,  12 C, and  12 D, and two platform bases  14 A,  14 B of an overall square configuration but having an opening extending in from one side to create a general U-shape. 
         [0033]    All of the platform bases  12 A- 12 D and  14 A,  14 B rest on the factory floor  16 , held together in contact with one another with one or more sides aligned and abutting with one or more sides of adjacent platform bases  12  or  14 . This forms an array of fit together platform bases  12 ,  14  which have a fixed spatial relationship with each other, established by the contact of respective sides. The array of platform bases  12 ,  14  are held in their relative in contact positions, as by the use of connector plates  34  which overlap adjacent sides of abutting platform bases  12 ,  14  which are fixed thereto with screws threaded into holes extending into the top of adjacent platform bases  12 ,  14 . Preferably, in order to minimize field operations only one platform base  12 A may be anchored to the floor, platform base  12 A, preferably the platform base associated with the robot module  18 , which has mounted thereon a commercially available robot  20 , equipped with a pickup gripper  22  for holding items to be palletized. 
         [0034]    As seen in  FIG. 8 , the robot module platform base  12 A has pairs of short angled channel sections  24  projecting from each side each of which have bottom holes allowing lag bolts to be inserted and received in anchors (not shown) installed in holes drilled in the floor  16 , fixing the platform base  12 A thereto. 
         [0035]    As seen in  FIG. 3 , all of the platform bases  12  are comprised of a top plate  26 , preferably on the order of 78 inches square which size will effectively accommodate the range of motion of most commercially available robots. The platform bases  12 ,  14  are preferably made of structural steel, the top plate  26  of each approximately one half inch thick so as to be able to provide a rigid support for the loads and equipment to be placed thereon by the usual. A square shape of the platform bases  12  allows any side thereof to be abutted and aligned with any side of any other platform base  12 ,  14 , maximizing the number of possible arrangements of such platform bases  12 ,  14  in an array. 
         [0036]    The top plates  26  are supported spaced above the floor  16  by a series of channel sections  28 ,  30  located beneath the outer edge of each side of the top plate  16 , welded in position with the open side facing inwardly. The longer channel sections  28  are each located at the middle of each side substantially flush with the outer edge thereof. Shorter sections  30  are mitered together and attached beneath each corner as seen in  FIG. 3 . A pair of spaces  32  are provided between the ends of the channel sections  28 ,  30  spaced apart and sized to enable the fork bars of a lift truck to be received therein for lifting and transporting the platform bases  12  or  14 . 
         [0037]    The short angled channel pieces  24  of the platform base  12 A for the robot module  18  fit into these spaces  30  but are turned out so as to form an opening which still allows fork lift handling of the robot modules  18  during assembly of the cell  10 . 
         [0038]    As seen in  FIGS. 3A and 3B , a tapped three hole pattern  38  is premachined centered along each side, matched to slots  36  in opposite sides elongated connector plates  34  which are used to held the platform bases  12 ,  14  together with respective sides aligned and in contact with each other to be indirectly located with respect to the robot module base plate  12 A. The connector plates  34  each have a series of three slots  36  extending in from each side, spaced and sized to receive bolts  37  installed in the holes  38 . 
         [0039]    The top plates  26  also are premachined with three small tapped hole patterns  40  at each corner. 
         [0040]    These are used to attach safety screen upright supports  42  which each have a flat mounting plate  43  fixed to the bottom end of the supports  42  as shown in  FIG. 1 . The safety screens  44  are installed along the outer side of the platform bases  12 ,  14  sized to extend across the entire length thereof, and blocking access to spaces within the palletizing cell  10 . 
         [0041]    The platform bases  14 A,  14 B shown in  FIG. 5  are of the same overall size as platform bases  12  (78 inches square) but have a large opening  57  extending in from one side to create a general U-shape, designed to receive a pallet to allow a product to be stacked on a pallet disposed directly on the floor surface  16 . 
         [0042]    Platform bases  14 A,  14 B are also constructed of a structural steel with a top plate  48  having inwardly facing four inch high rectangular tube sections  50 ,  52  welded to the underside of the three complete sides of the top plate  48 . Spaces between the tube sections  50 ,  52  allow fork lift pickup as with the platform bases  12 . 
         [0043]    Pallet guide structures  54  are affixed to the inside of each of the three complete sides  46 A,  46 B,  46 C having adjustable spacer plates  56  mounted thereto. 
         [0044]    A tapped hole pattern may be premachined into the top plate  48  at the outer ends and the corners for mounting safety fence sections as well as a three hole pattern for the connecting plates along the middle of sides  46 A,  46 B,  46 C. 
         [0045]    Since the base platforms  14 A,  14 B must be unfenced at the outer end to allow fork truck access to a pallet or a pallet stack  62  shown in  FIG. 10 , light curtain sensor tubes  60  are required, which are well known commercially available devices which detect any intrusion into the interior of the palletizer cell ( FIG. 10 ) through the opening, in the well known manner. 
         [0046]    In the configuration of the palletizer cell shown in  FIG. 1 , two open sided platform bases  14 A,  14 B are included one on each side of the robot module  18  to accommodate a pallet on which a product stack is built. 
         [0047]    A controls cabinet  64  may be located on an auxiliary platform  66 , or optionally, directly on the factory floor  16 . 
         [0048]    A double pick module  68  is located opposite the robot module  18 , comprised of a platform base  12 B, having two side by side product conveyors  70 A,  70 B using a 24 volt motorized roller drive. Products are thereby alternately presented to the robot  20  from conveyors  70 A,  70 B loaded through an opening  73  in safety fence section  72  attached to the outer side of the platform base  12 B. Product sensing photoeyes would be provided in the conventional manner to detect the presence of a product to be palletized. 
         [0049]    Platform bases  12 C and  12 D with two fence sections  74 ,  76  and  78 ,  80  define protected access clearance spaces for keeping personnel out of those spaces through which the pick and place motions of the robot  20  occur. Thus, the in contact platform bases  12 C,  12 D define the proper spaces on either side of the conveyors  70 A,  70 B. The abutment and alignment of platform bases  12 A and  12 B locate the conveyors  70 A,  70 B with respect to the robot  20 ; and abutment of  14 A,  14 B with  12 A properly locate the pallet receiving opening with respect to the robot  20  and conveyors  70 A,  70 B. Thus, the simple placement of the platform bases  12 ,  14  in contact with each other properly locates in the field the palletizer components of the cell  10  in relation to each other. 
         [0050]    The robotic palletizer cell  82  shown in  FIG. 2  includes the robot module  18  but it is placed at the rear of the cell  10 , with a platform base  14 A directly at the front. A single pick module  84  is located to one side, including a single pick powered conveyor  86  located aligned with an opening  88  in the safety fence  100 . 
         [0051]    A slip sheet module  90  is also included in the cell  82 , located next to the single pick module  84 . A slip sheet bin  92  rests atop a platform base  12 E with adjustable guides  94  and a “low sheet” sensing photoeye (not shown) provided according to conventional practice. 
         [0052]    Safety fence sections  96 ,  97  are mounted on sides of platform  12 A, fence sections  100 ,  102  on two sides of platform base  12 F, fence section  104  on one side of platform base  12 E, and fence section  106  on one side of platform base  14 A. An access gate  98  supported by uprights  43  between fence sections  4 S supported by uprights  42 , 43  may be included on one side of the platform base  12 E for loading slip sheets onto line  92 . 
         [0053]    An open sided platform base  14 A is located next to the slip sheet module  90  configured with adjustable plates  56  as in the cell  10  shown in  FIG. 1 , with light curtain tubes  60  to protect against access through the unfenced opening. 
         [0054]    The robot module  18  is bolted to the floor  16  with the other modules  84 ,  90 ,  14  anchored by being connected to the robot module, greatly simplifying installation of the cells  10 ,  82 . 
         [0055]    All of the components are thus fixed in the proper location disconnected with respect to each other by the fitting together and aligning of the various platform bases  12 ,  14  when assembled on the factory floor  16  held in mutually contacting position thereon. 
         [0056]    It is possible that anchoring of additional platform bases  12  to the factory floor  16  may be carried out in order to hold the platform bases together in the array, however, this is not preferred as installation of the connector plates  34  is quicker and easier. 
         [0057]    Other modules can be provided, including other equipment mounted to a standard platform bases  12 , such as a discharge module  100  ( FIG. 11 ) having a powered discharge conveyor  103  which allows powered transfer of loaded pallets. 
         [0058]    Electrical lines to the photocells, electric motors, light curtains can be routed in conduits or covered channels extending along the sides of the platform bases  12 ,  14  (not shown). 
         [0059]    The palletizer cells  10 ,  82  would normally first be assembled by the manufacturer in its shop, with the necessary wiring run to enable actual start up and trial before installation in the location where the cell is to be operated. The respective platform bases  12 ,  14  would then be disconnected for shipping to the final destination. The wiring would be disconnected left in the channels on the respective platform bases  12 ,  14 . 
         [0060]    Thus, when the platform bases  12 ,  14  are reassembled into the array, the proper locations of all of the components are automatically established by the interfitting of platform base. Likewise, the wiring needs only be reconnected, eliminating the need for running wiring in the field.