System and method for forming and moving an article array

A system for forming and moving an article array including a consolidation area having a support surface for receiving and arranging rows of articles to form an article array from an article row delivery device while the consolidation area continuously stabilizingly supports the periphery of the article rows positioned on the support surface as the article rows are arranged to form the article array.

FIELD OF THE INVENTION

The present invention is directed to a system and method for equipment associated with loading and unloading palletizing article arrays or portions thereof.

BACKGROUND OF THE INVENTION

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 and/or to reduce the amount of shipping material consumed, 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 dedicated machinery onto pallets.

It would be beneficial to develop and use a system and method for loading/unloading article array heads.

BRIEF DESCRIPTION OF THE INVENTION

In an embodiment, a method for forming and moving an article array includes receiving a first row of articles onto a support surface of a consolidation area between a movable stabilizer and a movable backing plate, the consolidation area providing continuous stabilizing support to the periphery of the first row of articles, the stabilizer and the backing plate providing stabilizing support to opposed portions of the periphery of the first row of articles. The method further includes the backing plate and the stabilizer moving and stabilizingly supporting the first row of articles in a first direction. The method further includes additionally stabilizingly supporting the portion of the periphery of the first row of articles stabilizingly supported by the backing plate, the additional stabilizing support being independent of the stabilizing support provided by the backing plate. The method further includes moving the backing plate in a direction opposite the first direction in preparation of receiving a second row of articles. The method further includes receiving the second row of articles immediately adjacent the first row of articles onto the support surface between the backing plate and the first row of articles, the periphery of the first row of articles and the second row of articles being continuously stabilizingly supported, including stabilizing support provided by the stabilizer and the backing plate, the first row of articles and the second row of articles forming an article array. The method further includes removing the additional stabilizing support from the portion of the periphery of the first row of articles formerly stabilizingly supported by the backing plate, the portion of the periphery of the first row of articles formerly stabilizingly supported by the backing plate being stabilizingly supported by a corresponding portion of the periphery of the second row of articles, and a portion of the periphery of the second row of articles being stabilizingly supported by the backing plate. The method further includes moving the article array toward a collection area.

In another embodiment, a method for forming and moving an article array including receiving a first row of articles onto a support surface of a consolidation area between a movable stabilizer and a movable backing plate, the stabilizer and the backing plate each having an axis along its length, the first row of articles being received from a direction that is substantially perpendicular to each axis of the stabilizer and the backing plate, the consolidation area providing continuous stabilizing support to the periphery of the first row of articles, the stabilizer and the backing plate providing stabilizing support to opposed portions of the periphery of the first row of articles. The method further includes the backing plate and the stabilizer moving and stabilizingly supporting the first row of articles in a first direction from the same direction as the first row of articles. The method further includes additionally stabilizingly supporting the portion of the periphery of the first row of articles stabilizingly supported by the backing plate, the additional stabilizing support being independent of the stabilizing support provided by the backing plate. The method further includes moving the backing plate in a direction opposite the first direction in preparation of receiving a second row of articles from the same direction as the first row of articles. The method further includes receiving the second row of articles immediately adjacent the first row of articles onto the support surface between the backing plate and the first row of articles, the periphery of the first row of articles and the second row of articles being continuously stabilizingly supported, including stabilizing support provided by the stabilizer and the backing plate, the first row of articles and the second row of articles forming an article array. The method further includes removing the additional stabilizing support from the portion of the periphery of the first row of articles formerly stabilizingly supported by the backing plate, the portion of the periphery of the first row of articles formerly stabilizingly supported by the backing plate being stabilizingly supported by a corresponding portion of the periphery of the second row of articles, and a portion of the periphery of the second row of articles being stabilizingly supported by the backing plate. The method further includes moving the article array to a collection area.

In yet another embodiment, a system for forming and moving an article array including a consolidation area having a support surface for receiving and arranging rows of articles to form an article array from an article row delivery device while the consolidation area continuously stabilizingly supports the periphery of the article rows positioned on the support surface as the article rows are arranged to form the article array. The consolidation area including a backing plate and a first stabilizer, the article rows positioned between the backing plate and first stabilizer, the backing plate and the stabilizer providing stabilizing support to opposed portions of the periphery of the article rows. Upon the first stabilizer and the backing plate moving and stabilizingly supporting the article rows in a first direction while forming the article array, a second stabilizer provides independent stabilizing support to the portion of the periphery of the article rows stabilizingly supported by the backing plate prior to the backing plate moving in a direction opposite the first direction, in preparation of receiving additional article rows in the consolidation area immediately adjacent the article rows already positioned on the support surface for forming the article array. Upon formation of the article array, the second stabilizer discontinues providing stabilizing support to the portion of the periphery of article rows formerly stabilizingly supported by the backing plate, the portion of the periphery of the first row of articles formerly stabilizingly supported by the backing plate being stabilizingly supported by a corresponding portion of the periphery of the additional rows of articles, and a portion of the periphery of the additional row of articles being stabilizingly supported by the backing plate. An article array moving device is provided for moving the article array from the consolidation area toward the collection area.

DETAILED DESCRIPTION OF THE INVENTION

Referring toFIG. 1, an automated palletizer system or palletizer10utilizing an article array forming/moving system12is shown. Article array forming/moving system12receives articles14(FIG. 4), and more specifically, article rows16(FIG. 4) from an article row delivery device18, such as a conveyor for forming article arrays22(FIG. 18) that are moved to a collection area26(FIG. 1) such as a container or a tray (e.g., having a bottom surface and short peripheral walls extending upwardly from the bottom surface), by a article array moving device28movable by an anthropomorphic robotic arm30. As shown inFIG. 1, once container or collection area26is filled with article arrays22and closed, the container or collection area26is moved via a conveyor32for shipping. In other palletizing embodiments, the components may by arranged differently. Other exemplary embodiments of associated components of palletizer10will be discussed in further detail below.

For purposes herein, the term “article row” may be used irrespective the number of articles rows being gripped, moved or otherwise manipulated. In other words, the term “article row” may be used irrespective a single row of articles or article row16(FIG. 22), a pair of rows of articles or article row pairs17(FIG. 18) or more than two pairs of article rows or an array of articles or article array22(FIG. 4) being gripped, moved or otherwise manipulated. Similarly, the term “article array” may refer to two or more article rows, although the term “partial article array” may be used to refer to an article array already having two or more article rows, but undergoing further loading or building of article rows, thereby further building, loading or enlarging the existing article array. The terms “gripped” and “manipulated” and “moved” and the like in the context of the interaction between the article row delivery device and the article row(s) may be used interchangeably.

FIG. 2shows an article array forming/moving system112configured to receive successive article rows16(FIG. 22) from article row delivery device118for forming the article array22(FIG. 29) in consolidation area138prior to moving the article array22to collection area126, such as a bagging area.

FIG. 3shows an article array forming/moving system112configured to receive successive article rows16(FIG. 22) from article row delivery device118for forming the article array22(FIG. 29) in consolidation area138prior to moving the article array22to collection area226, such as onto a slip sheet172(FIG. 34).

FIG. 4shows article array forming/moving system12that is configured to receive an article row pair17or pair of article rows16from article row delivery device18. As shown inFIG. 4, article row delivery device18is a conveyor used in combination with an article row handling device34. Article row handling device34receives article row pair17from article row delivery device18, and then places the article row pair17onto a support surface36of a consolidation area38. In another embodiment, the article row delivery device can include an article array head, such as article array moving device28(FIG. 1) used in combination with an article row delivery device18or other article row delivery source.

FIGS. 5-17sequentially show the operation of article array forming/moving system12(FIG. 4). It is to be understood that the exemplary sequential operation movements shown inFIGS. 5-17(as well as other exemplary operational movements discussed in further detail below) may at least partially occur simultaneously or in an order different than that discussed. As shown inFIG. 5, the exemplary article row handling device34includes a clamping head40having a pair of gripping jaws for engaging each article row16of article row pair17received from article row delivery device18. In one embodiment, the clamping head may be able to engage a different number of article rows, such as the number of article rows provided from the article row delivery device.

Once clamping head40engages article row pair17received from article row delivery device18, then as shown inFIG. 6, article row handling device34raises article row pair17in a vertical direction42away from article row delivery device18.

Once article row handling device34raises article row pair17away from article row delivery device18, then as shown inFIG. 7, article row handling device34moves article row pair17in a horizontal direction44away from article row delivery device18until article row pair17is vertically positioned over a support surface36of consolidation area38and between a backing plate46and a stabilizer48. Consolidation area38includes support surface36, backing plate46and stabilizer48and other components as will be discussed in further detail below.

Once article row pair17is vertically positioned over support surface36of consolidation area38and between backing plate46and stabilizer48, then as shown inFIG. 8, clamping head40of article row handling device34moves article row pair17in a vertical direction42between backing plate46and stabilizer48until article row pair17contacts and is vertically supported by support surface36of consolidation area38.

Once article row pair17contacts and is vertically supported by support service36of consolidation area38, then as shown inFIG. 9, clamping head40of article row handling device34is disengaged from article row pair17and moves in vertical direction42away from the article row pair. As a result, article row pair17is vertically supported by support surface36and the periphery of article row pair17is stabilizingly supported by consolidation area38, which includes backing plate46, stabilizer48, and opposed support members50(FIG. 4).

For purposes herein, “stabilizingly supported” and variations thereof refer to support provided to at least the periphery of the article row(s) such as to prevent tipping of the articles. For example, such stabilizing support may include, but is not limited to lateral support, including support forces directed substantially perpendicular to the support surface of the consolidation area, and vertical compressive support forces applied to opposed ends of the article row(s), such as applied by clamping head40to corresponding ends of article row pair17opposite support surface36, such as shown inFIG. 8.

Once clamping head40of article row handling device34is disengaged from article row pair17, and vertically moved away from article row pair17, then as shown inFIG. 10, article row handling device34moves in horizontal direction44away from article row pair17in preparation of engaging another article row pair17received from article row delivery device18(FIG. 5) as previously discussed.

Once article row handling device34moves away from article row pair17, then as shown inFIG. 11, backing plate46and stabilizer48move and stabilizingly support opposed portions of the periphery of article row pair17(FIG. 10) in a horizontal direction44away from article row handling device34, becoming already positioned article rows19, with support members50(FIG. 4) of consolidation area38providing stabilizing support of the remaining portions of the periphery of already positioned article rows19. In other words, article row pair17and already positioned article rows19are each continuously stabilizingly supported by the backing plate46, stabilizer48and consolidation area38.

Once article row pair17has been moved and continuously stabilizingly supported to become continuously stabilizingly supported already positioned article rows19, then as shown inFIG. 12A, stabilizer52moves a stabilizer bar56in vertical direction42until stabilizer bar56achieves a stabilizing position54, applying a vertical compressive stabilizing force to at least a portion of the periphery of the already positioned article rows19. Stabilizer52provides an additional, independent stabilizing support to at least the portion of the periphery of the already positioned article rows19simultaneously stabilizingly supported by backing plate46. Article row handling device34moves another article row pair17in horizontal direction44toward already positioned article rows19.

Once stabilizer bar56achieves stabilizing position54, then as shown inFIG. 12B, backing plate46moves in horizontal direction44away from the already positioned article rows19, and article row handling device34moves article row pair17in horizontal direction44until article row pair17is immediately adjacent to already positioned article rows19and vertically positioned between backing plate46and the already positioned article rows19.

Once article row pair17is immediately adjacent to already positioned article rows19, then as shown inFIG. 13, clamping head40of article row handling device34moves in vertical direction42between backing plate46and already positioned article rows19until article row pair17contacts and is vertically supported by support surface36of consolidation area38. As a result of this arrangement, article row pair17being immediately adjacent to already positioned article rows19, article row pair17stabilizingly supports already positioned article rows19, becoming a portable article array20. In one embodiment, article row pair17contacts and compressively secures already positioned article rows19while becoming partial article array20. Opposed portions of the periphery of partial article array20are stabilizingly supported by backing plate46and stabilizer48, as well as support members50(FIG. 4) stabilizingly supporting the remaining portions of the periphery of partial article array20. As a result, partial article array20is continuously stabilizingly supported by backing plate46, stabilizer48and consolidation area38.

Once partial article array20has been formed, then as shown inFIG. 14, stabilizer bar56is moved in vertical direction42away from and disengaging partial article array20. In one embodiment, stabilizer52is moved in one or more of vertical and horizontal directions such that the stabilizer is moved out of the path of an article array prior to the article array reaching a collection area, as will be discussed in further detail below. Despite disengagement from stabilizer bar56, partial article array20is continuously stabilizingly supported by backing plate46, stabilizer48and consolidation area38.

Once stabilizer bar56has been disengaged from partial article array20, then as shown inFIG. 15, backing plate46and stabilizer48move and stabilizingly support opposed portions of the periphery of partial article array20in a horizontal direction44away from article row handling device34in preparation of adding additional article row pair(s)17, such as previously discussed and shown inFIGS. 11-14. The periphery of partial article array20is continuously stabilizingly supported by the backing plate46, stabilizer48and consolidation area38, as previously discussed.

FIG. 16shows a fully formed or completely built-up or loaded article array22that is continuously stabilizingly supported by consolidation area38, having been continuously stabilizingly supported during the build-up or loading of article array22.

Once article array22has been formed, then as shown inFIG. 17, backing plate46and stabilizer48move and stabilizingly support opposed portions of the periphery of article array22in horizontal direction44away from stabilizer52in preparation of moving article array22to collection area26(e.g.,FIG. 1).FIG. 20Ais a plan view of the periphery of article array22continuously stabilizingly supported by the backing plate46, stabilizer48and consolidation area38, as previously discussed, having a distance58between backing plate46and stabilizer48.FIG. 20Bis a plan view of the periphery of article array22that is similar toFIG. 20A, except that backing plate46and stabilizer48are moved toward each other such that the distance therebetween is reduced, such as to a distance60, thereby reducing the vertical cross section of article array22. It may be desirable to reduce the vertical cross section of article array22when the article array moving device28utilized is an article array head, as shown inFIG. 18for reasons such as facilitating moving the article array to a collection area26, such as inside of a container having an opening of a fixed size. Upon being moved inside the container, the article array cross section would elastically increase to the extent possible inside of the container, providing increased stability of the article array inside of the container.

Once article array22has been moved, then as shown inFIG. 18, article array moving device28, such as an article array head is vertically aligned with article array22.

Once article array moving device is vertically aligned with article array22, then as shown inFIG. 19, article array moving device28is moved in vertical direction42until engaging article array22.FIG. 21shows article array moving device28lifting and moving article array22from support surface36of consolidation area38toward a collection area26(FIG. 1).

In one embodiment, stabilizer52may be moved in one or more of vertical and horizontal directions such that stabilizer52is moved out of the path of article array22prior to the article array22reaching a collection area. For example, such as shown inFIG. 15, if stabilizer52were moved such that article array22is vertically accessible by article array moving device28(FIG. 18), it may be possible to eliminate further movement of the article array, as shown inFIG. 18, i.e., the backing plate46and stabilizer48moving and stabilizingly supporting opposed portions of the periphery of article array22in horizontal direction44away from stabilizer52in preparation of moving article array22to collection area26(e.g.,FIG. 1).

FIGS. 22-28sequentially show the operation of article array forming/moving system112, such as shown inFIG. 2. It is to be understood that the exemplary sequential operation movements shown inFIGS. 22-28may at least partially occur simultaneously or in an order different than that discussed. As shown inFIG. 22, article row16is received from article row delivery device118, such as a conveyor. In one embodiment, article row delivery device118may provide more than one article row16.

Once article row16is received from article row delivery device118, as further shown inFIG. 22, article row16is stabilizingly supported by backing plate146and stabilizer152.

Once article row16is stabilizingly supported, then as shown inFIG. 23, stabilizer152is moved in vertical direction142until stabilizer152is in a retracted position that is substantially flush with the surface of article row delivery device118and support surface136of consolidation area138. In one embodiment, stabilizer152may be rotated to achieve a retracted position that is substantially flush relative to the surface of article row delivery device118and support surface136. By virtue of the close proximity of stabilizer152and stabilizer148, even with stabilizer152retracted, the periphery of article row16remains continuously stabilizingly supported by backing plate146, stabilizer148and consolidation area138. Consolidation area138includes support surface136, backing plate146, stabilizer148, support members150(FIG. 29) and other components as will be discussed in further detail below.

Once stabilizer152is in a retracted position, then as shown inFIG. 24, backing plate146and stabilizer148move and stabilizingly support opposed portions of the periphery of article row16in a horizontal direction144away from article row delivery device118and over retracted stabilizer152. Article row16is then further moved in a horizontal direction144until reaching an extended predetermined position160(FIG. 25).

Once article row16reaches extended predetermined position160, then as shown inFIG. 25, stabilizer152is moved in vertical direction142to an extended position either prior to or substantially simultaneously with backing plate146moving in horizontal direction144away from article row16, until backing plate146reaches a starting position or home position162. In either event, stabilizer152provides an additional, independent stabilizing support to at least the portion of the periphery of article row16simultaneously stabilizingly supported by backing plate146.

Once stabilizer152is in an extended position and backing plate146is in home position162, then as shown inFIG. 26, an additional article row16is received from article row delivery device118, the article rows16becoming an article row pair17.

Once article row pair17has been formed, then as shown inFIG. 27, stabilizer152is moved in vertical direction142to its retracted position.

Once stabilizer152is retracted, then as shown inFIG. 28, backing plate146and stabilizer148move and stabilizingly support opposed portions of the periphery of article row pair17in a horizontal direction144away from article row delivery device118and over retracted stabilizer152, article row pair17becoming partial article array20. Depending upon the geometry of the articles, such as a circular cross section, adjacent article rows may partially overlap one another to form a more compact, stable arrangement, such as shown inFIG. 29for article array22.

Once partial article array20has been formed, additional article rows16are added, such as previously discussed and shown inFIGS. 25-28, forming article array22as shown inFIG. 29.

Once article array22has been formed, then as shown inFIG. 30, backing plate146and stabilizer148move and stabilizingly support opposed portions of the periphery of article array22in a horizontal direction144toward an end164of support surface136of consolidation area138in preparation of moving article array22from consolidation area138to a collection area126,226(see respectiveFIGS. 2, 3). The periphery of article array22is continuously stabilizingly supported by backing plate146, stabilizer148, and consolidation area138, which includes support members (FIG. 29), as previously discussed.

As shown inFIG. 31, as backing plate146and stabilizer148move and stabilizingly support opposed portions of the periphery of partial article array20in horizontal direction144toward end164of support surface136of consolidation area138in preparation of moving article array22from consolidation area138to a collection area126,226(see respectiveFIGS. 32, 34), stabilizer148selectively retracts in a vertical direction142, becoming substantially flush with support surface136.

As shown inFIG. 32, which is an extended side view ofFIG. 31, article array22is moved in horizontal direction144toward collection area126, which is a bagging area. As further shown inFIG. 32, the periphery of article array22in close proximity to retracted stabilizer148is continuously stabilizingly supported as a result of its close proximity to film170of bagging area or collection area126.FIG. 33shows article array22further directed into collection area126and further surrounded by film170, ultimately becoming a bagged article array (not shown).

FIG. 34is similar toFIG. 33, except that article array22is being directed into collection area226, such as an area including a slip sheet172. A further difference with collection area226is that an additional stabilizer174is required to ensure article array22is continuously stabilizingly supported while being moved from consolidation area138to collection area226.

FIG. 35shows an embodiment of consolidation area138in which portions of support surface136are pivotably connected to corresponding actuators168. During normal operation, actuators168are maintained in an extended position, securing the portions of support surface136in a horizontal position for supporting an article array. However, for reasons such as partial tipping of articles of the article array22, the presence of defective articles or for other reasons, actuators168are selectively urged toward a retracted position such that at least sufficient portions of support surface136subtend an angle with a horizontal plane sufficient to remove all articles on the portions of support surface136by force of gravity, thereby preventing all articles of the article array22from being movable to the collection area. This support surface construction resembles bombardier doors of an aircraft. In another embodiment, a single actuator may be utilized to support a support surface of unitary construction. In another embodiment, support surface136may include more than two portions, each having corresponding actuators.

While the invention has been described with reference to one or more embodiments, 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. In addition, all numerical values identified in the detailed description shall be interpreted as though the precise and approximate values are both expressly identified.