Method for forming an article array

A method for building an article array comprised of (n) rows of articles, as disclosed herein.

FIELD OF THE INVENTION

The present invention is directed to a method for forming an article array for ultimately palletizing articles, and specifically to a method for forming an article array for ultimately palletizing articles while using the same head for differently sized articles.

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, 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 using specialized end of arm tooling or article head usable only on one article having a particular size/shape. That is, additional article heads must be specially constructed for each different article to be manipulated, which can be expensive, and could disrupt operations until a compatible article head is made available. Moreover, this operating limitation could prevent the ability to accommodate “special one-time runs” for a small amount of uniquely sized articles, such as for reasons including cost and time delays in obtaining a specialized head.

What is needed is a method for palletizing articles that does not suffer from these drawbacks.

SUMMARY OF THE INVENTION

The present invention further relates to a method for building an article array comprised of (n) rows of articles, the steps including:(a) positioning a head having a pair of opposed substantially planar gripping members such that the pair of gripping members at least partially laterally surrounds a first row of first articles at a first location, the first location having a horizontal first support surface for supporting the first row of first articles;(b) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the first row of first articles;(c) transporting the first row of first articles from the first location to a second location, the second location having a horizontal second support surface for supporting the first row of first articles;(d) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the first row of first articles;(e) positioning the head such that the pair of gripping members at least partially laterally surrounds a second row of first articles at the first location;(f) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the second row of first articles;(g) transporting the second row of first articles from the first location to the second location in close proximity to the first row of first articles, the first row of first articles and the second row of first articles having one of at least a first arrangement, a second arrangement, and a third arrangement;(h) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the second row of first articles;(i) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface in response to the first row of first articles and the second row of first articles having the first arrangement or the second arrangement, in response to the first row of first articles and the second row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface is optional;(j) moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the second row of first articles to move in the lateral direction toward the first row of first articles in response to the first row of first articles and the second row of first articles having the first arrangement or the second arrangement, the first row of first articles and the second row of first articles forming a partial article array, in response to the first row and the second row of first articles having the third arrangement, moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the second row of first articles to move in the lateral direction toward the first row of first articles is optional;(k) repeating steps (e)-(j) until a partial article array is formed including an (n−1) row of first articles;(l) positioning the head such that the pair of gripping members at least partially laterally surrounds an (n) row of first articles at the first location;(m) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (n) row of first articles;(n) transporting the (n) row of first articles from the first location to the second location in close proximity to the partial article array including the (n−1) row of first articles;(o) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (n) row of first articles;(p) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface in response to the partial article array including the (n−1) row of first articles and the (n) row of first articles having the first arrangement or the second arrangement, in response to the partial article array including the (n−1) row of first articles and the (n) row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface is optional; and(q) moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the (n) row of first articles to move in the lateral direction toward the partial article array including the (n−1) row of first articles in response to the partial article array including the (n−1) row of first articles and the (n) row of first articles having the first arrangement or the second arrangement, the partial article array including the (n−1) row of first articles and the (n) row of first articles forming the article array.

In response to the partial article array including the (n−1) row of first articles and the (n) row of first articles having the third arrangement, moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the (n) row of first articles to move in the lateral direction toward the partial article array including the (n−1) row of first articles is optional, the partial article array including the (n−1) row of first articles and the (n) row of first articles forming the article array.

The present invention yet further relates to a method of building a pallet comprised of article arrays, each article array having a plurality of article rows comprised of first articles extending in one of an x-direction and a y-direction within a rectangular areal footprint in the x-direction and the y-direction, including:(a) inputting parameters including a height dimension, a width dimension and a length dimension of a first article, a dimension of the rectangular areal footprint in the x-direction, a dimension of the rectangular areal footprint in the y-direction, a dimension of a width of article rows to be provided from an article row source, a type of arrangement to be used between adjacent article rows for building the first article arrays, the direction (x-direction or y-direction) and length dimension of the article rows;(b) in response to the parameters being input, a controller controls a number of articles contained in a first row of first articles, and each subsequent row of first articles, at a first location having a horizontal first support surface for supporting each row of first articles;(c) positioning a head having a pair of opposed substantially planar gripping members such that the pair of gripping members at least partially laterally surrounds the first row of first articles at the first location;(d) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the first row of first articles;(e) transporting the first row of first articles from the first location to a second location, the second location having a horizontal second support surface for supporting the first row of first articles and each subsequent row of first articles, the first row of first articles positioned in the inputted direction;(f) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the first row of first articles;(g) positioning the head such that the pair of gripping members at least partially laterally surrounds a second row of first articles at the first location;(h) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the second row of first articles;(i) transporting the second row of first articles from the first location to the second location in close proximity to the first row of first articles, the first row of first articles and the second row of first articles having an inputted type of arrangement of one of at least a first arrangement, a second arrangement and a third arrangement;(j) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the second row of first articles;(k) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface in response to the first row of first articles and the second row of first articles having the first arrangement or the second arrangement, in response to the first row of first articles and the second row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface is optional;(l) moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the second row of first articles to move in the lateral direction toward the first row of first articles in response to the first row of first articles and the second row of first articles having the first arrangement or the second arrangement, the first row of first articles and the second row of first articles forming a first partial article array, in response to the first row and the second row of first articles having the third arrangement, moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the second row of first articles to move in the lateral direction toward the first row of first articles is optional;(m) repeating steps (g)-(l) until a first partial article array is formed including an (n−1) row of first articles;(n) positioning the head such that the pair of gripping members at least partially laterally surrounds an (n) row of first articles at the first location;(o) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (n) row of first articles;(p) transporting the (n) row of first articles from the first location to the second location in close proximity to the first partial article array including the (n−1) row of first articles;(q) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (n) row of first articles;(r) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface in response to the first partial article array including the (n−1) row of first articles and the (n) row of first articles having the first arrangement or the second arrangement, in response to the first partial article array including the (n−1) row of first articles and the (n) row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface is optional;(s) moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the (n) row of first articles to move in the lateral direction toward the first partial article array including the (n−1) row of first articles in response to the first partial article array including the (n−1) row of first articles and the (n) row of first articles having the first arrangement or the second arrangement, the first partial article array including the (n−1) row of first articles and the (n) row of first articles forming a first article array,in response to the first partial article array including the (n−1) row of first articles and the (n) row of first articles having the third arrangement, moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the (n) row of first articles to move in the lateral direction toward the first partial article array including the (n−1) row of first articles is optional, the first partial article array including the (n−1) row of first articles and the (n) row of first articles forming the first article array;(t) moving the head to a third location to pick up one of a slip sheet and a tray;(u) placing the one of the slip sheet and the tray over the first article array;(v) positioning the head such that the pair of gripping members at least partially laterally surrounds an (n+1) row of first articles at the first location;(w) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (n+1) row of first articles;(x) transporting the (n+1) row of first articles from the first location to a fourth location, the fourth location being the one of the slip sheet and the tray having a horizontal third support surface for supporting the (n+1) row of first articles and each subsequent row of first articles;(y) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (n+1) row of first articles;(z) positioning the head such that the pair of gripping members at least partially laterally surrounds an (n+2) row of first articles at the first location;(aa) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (n+2) row of first articles;(ab) transporting the (n+2) row of first articles from the first location to the fourth location in close proximity to the (n+1) row of first articles, the (n+1) row of first articles and the (n+2) row of first articles having the inputted type of arrangement of one of at least the first arrangement, the second arrangement, and the third arrangement;(ac) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (n+2) row of first articles;(ad) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the third support surface in response to the (n+1) row of first articles and the (n+2) row of first articles having the first arrangement or the second arrangement, in response to the (n+1) row of first articles and the (n+2) row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the third support surface is optional;(ae) moving the head in a lateral direction parallel to the third support surface such that the other one gripping member of the pair of gripping members urging the (n+2) row of first articles to move in the lateral direction toward the (n+1) row of first articles in response to the (n+1) row of first articles and the (n+2) row of first articles having the first arrangement or the second arrangement, the (n+1) row of first articles and the (n+2) row of first articles forming a second partial article array,in response to the (n+1) row and the (n+2) row of first articles having the third arrangement, moving the head in the lateral direction parallel to the third support surface such that the other one gripping member of the pair of gripping members urging the (n+2) row of first articles to move in the lateral direction toward the (n+1) row of first articles is optional;(af) repeating steps (z)-(ae) until a second partial article array is formed including a (2n−1) row of first articles;(ag) positioning the head such that the pair of gripping members at least partially laterally surrounds a (2n) row of first articles at the first location;(ah) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (2n) row of first articles;(ai) transporting the (2n) row of first articles from the first location to the fourth location in close proximity to the second partial article array including the (2n−1) row of first articles;(aj) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (2n) row of first articles;(ak) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the third support surface in response to the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles having the first arrangement or the second arrangement, in response to the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the third support surface is optional;(al) moving the head in a lateral direction parallel to the third support surface such that the other one gripping member of the pair of gripping members urging the (2n) row of first articles to move in the lateral direction toward the second partial article array including the (2n−1) row of first articles in response to the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles having the first arrangement or the second arrangement, the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles forming a second article array,in response to the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles having the third arrangement, moving the head in a lateral direction parallel to the third support surface such that the other one gripping member of the pair of gripping members urging the (2n) row of first articles to move in the lateral direction toward the second partial article array including the (2n−1) row of first articles is optional, the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles forming the second article array.(am) moving the head to a fourth location to pick up one of a top sheet and a tray; and(an) placing the one of the top sheet and the tray over the second article array.

DETAILED DESCRIPTION OF THE INVENTION

The present invention includes a method for constructing palletized articles10from article arrays16, which article arrays include a first article array44and a second article array46as shown inFIG.1. For purposes of discussion, first article array44generally corresponds to the bottom or lowest article array of palletized articles, and second article array46generally corresponds to the next lowest article array constructed on top of and is supported by first article array44. Palletized articles10are typically constructed by establishing a stacking area72(FIG.5) having a horizontal support surface, then positioning a pallet12over the stacking area. Pallet12is overlain with a covering18, such as a slip sheet, to provide a uniform substantially flat substantially horizontal surface on which to arrange and support articles14to form a first article layer or first article array44. Alternately, instead of a slip sheet, a tray having a peripheral flange or other component can be used to achieve separation between adjacent article arrays16.

The term “article array,” “article layer” and the like may be used interchangeably.

The terms “building” “constructing” and “forming” and the like as it pertains to any of article layers, article arrays and palletized articles may be used interchangeably.

The terms “article array16,” “article array44,” “first article array44,” “article array46,” “second article array46” and the like may generally refer to an article array, although (first) article array44and (second) article array46may also refer to the first two article arrays of a palletized article, such as depicted inFIG.1.

As shown inFIG.2, article14includes a vertical height22, a lateral or horizontal width24and a lateral or horizontal length26, each of which are mutually perpendicular to each other. For purposes of discussion, width24and length26of article14extend in an x-direction and a respective y-direction and have a corresponding lateral or horizontal areal footprint occupying a portion of the total horizontal rectangular areal footprint of an article array. In one embodiment, width24and length26are the same (e.g., circular or square profiles). For example, as shown inFIG.3A, covering or slip sheet18has an x-direction dimension28and a y-dimension30, with the resulting product of these dimensions28,30defining a rectangular areal footprint in the x-direction and the y-direction. For purposes of discussion and consistency only, the origin of the x-axis and y-axis corresponds to the lower left hand side of covering or slip sheet18. Article rows A through N extending in the x-direction collectively form first article array44. As shown, cylindrically shaped articles14have respective dimensions of width24and length26that are the same.FIG.3Afurther shows adjacent rows A through N which are alternately staggered, as a result of positioning alternating rows with an x-direction offset36. The rows A through N not subjected to the x-direction offset36are positioned having an x-direction edge distance32from a corresponding edge of slip sheet18. In one embodiment, the rows A through N which are subjected to the x-direction offset36are positioned having an x-direction edge distance from a corresponding edge of slip sheet18that is equal to x-direction edge distance32. As shown inFIG.3A, row N is positioned having a y-direction edge distance34from a corresponding edge of slip sheet18. In one embodiment, each of rows A through N have the same y-direction edge distance34.FIG.3Ashows an overlap50measured in the y-direction between adjacent rows A through N. As a result of overlaps50, the first article array44ofFIG.3Adefines a nested arrangement.

Optionally, as shown inFIG.3B, which is an enlarged, partial view of an alternate embodiment of article array44taken from region3B ofFIG.3A, instead of an overlap, a gap52is provided in the y-direction between adjacent rows A through N. As a result of gaps52, the first article array44ofFIG.3Bdefines a non-nested arrangement. Depending upon the magnitude of gaps52, the non-nested arrangement defines one of a non-nested closely spaced arrangement54or a non-nested non-closely spaced arrangement58. For purposes herein, gap52for the non-nested closely spaced arrangement54is negligible, i.e., between zero and less than the width of gripping member98(FIG.7) of article handling head90(FIG.6), while gap52for the non-nested non-closely spaced arrangement58is equal to or greater than the width of gripping member98(FIG.7) of article handling head90(FIG.6). These differing arrangements54,58require different manipulations of the pair of gripping members96(FIG.6) during the formation of the article arrays, as will be discussed in additional detail below.

In contrast toFIG.3A,FIG.3Cshows rows A through N extending in the y-direction, collectively forming first article array44having an x-direction edge distance38, a y-direction edge distance40, and a y-direction offset42from respective rows A through N, which are analogous to y-direction edge distance34, x-direction edge distance32, and x-direction offset36from respective rows A through N ofFIG.3A. For reasons to be discussed in additional detail below, the operator can choose which direction (x-direction or y-direction) the rows A through N are to extend.

FIG.4Ashows article rows A through N extending in the x-direction, each of the rows being mutually aligned with one another or having the same x-direction edge distance66from the corresponding edge of covering or slip sheet18, versus the x-direction offset36between alternate rows A through N ofFIG.3A. Additionally, as shown inFIG.4A, articles14are configured to have a width64that is different than its length62. Alternately, as shown inFIG.4B, articles14in their respective rows A through N can be arranged or rotated such that the articles have a width62that is different than its length64. As shown inFIG.4A, between each row of adjacent rows A through N is a gap56of negligible width.

Optionally, as shown inFIG.4C, which is an enlarged, partial view of an alternate embodiment of article array44taken from region4C ofFIG.4A, instead of a negligible gap56ofFIG.4A,FIG.4Cshows a gap60provided in the y-direction between adjacent rows A through N. As a result of gaps60, the first article array44ofFIG.4Adefines a non-nested arrangement. Depending upon the magnitude of gaps56,60the non-nested arrangement defines one of a non-nested closely spaced arrangement54or a non-nested non-closely spaced arrangement58. For purposes herein, gap56is between zero and less than the width of gripping member98(FIG.7) of article handling head90(FIG.6) and defines a non-nested closely spaced arrangement54, while gap60is greater than the width of gripping member98(FIG.7) of article handling head90(FIG.6) and defines a non-nested non-closely spaced arrangement58. These differing arrangements54,58require different manipulations of the pair of gripping members96(FIG.6) during the formation of the article arrays, as will be discussed in additional detail below.

FIG.5shows an exemplary robotic palletizing cell70for building palletized articles10(FIG.1). A control system or controller76, such as a microprocessor, controls the operation of components in palletizing cell70, including an operator interface77, all of which operates in a known manner and is not further discussed herein. Palletizing cell70includes a location or stacking area72that has a horizontal support surface for receiving a pallet12(FIG.1) and a covering or slip sheet18from a covering storage area19overlying pallet12for providing a horizontal support surface for the palletized articles10. Alternately, instead of a slip sheet, a tray having a peripheral flange or other component can be used to achieve separation between adjacent article arrays16(FIG.1). As further shown inFIG.5, palletizing cell70includes an article conveyor78extending to a collection area80which provides a horizontal surface for supporting an article row (e.g., article row148(FIG.9)) received from an article row source68to article conveyor78. A robot74such as an anthropomorphic robot includes an end effector or end of arm tooling or article handling head90for transporting or moving the article row from collection area80to stacking area72, becoming, for example, article row A (FIG.3A). Robot74directs article handling head90to subsequently transport additional article rows from collection area80to stacking area72, i.e., article rows B through N, forming first article array44(FIG.3A). Robot74then directs article handling head90to covering storage area19to receive a slip sheet18and then transport and overlay slip sheet18on first article array44(FIG.3A). A second article array46(FIG.3D) is then constructed by robot74directing article handling head90to sequentially transport article rows from collection area80to stacking area72, becoming article rows N+1 through 2N of the second article array46. Slip sheets18are inserted between subsequently constructed article arrays16(FIG.1), with the top article array being overlain with a top frame or covering20provided from covering storage area21, thereby completing the construction of palletized articles10.

As shown inFIG.6, article handling head or head90is now discussed. Head90includes a frame94having a fitting92for connecting to robot74(FIG.5) that manipulates head90for building palletized articles. Head90includes a pair of gripping members96comprising elongate substantially planar gripping members98,100. Gripping members98,100are maintained parallel to one another, which permits the gripping members to accommodate and manipulate differently sized articles capable of constructing one palletized article from a first article followed by constructing another palletized article from a different second article sized differently from the first article, or capable of constructing a palletized article such as by utilizing the first article for constructing an article array, and then utilizing the second article for constructing a different article array within the same palletized article without requiring a change-out of head90or modification of components, such as gripping members98,100, thereby saving down-time, and by minimizing the number of article handling heads90, reducing production costs. In one arrangement, gripping members98,100are positioned side-by-side at substantially the same vertical position relative to one another. Secured to frame94is a support structure101that further secures an end112of an actuator110, such as a pneumatic actuator, with the opposite end114of actuator110pivotably connected via a fastener118extending through mutually aligned openings of a pair of opposed brackets116and end114of actuator110. The opposed brackets116are secured to a flange108extending generally perpendicularly from gripping member98. Each of a pair of rods106secured at one end to flange108are slidably guided by a corresponding bearing104and block107secured to support structure101. As a result of the distance between ends112,114of actuator110being changed during operation of actuator110, gripping member98is actuated along guided movement direction84(FIG.7), raising gripping member98vertically above gripping member100.

As shown collectively inFIGS.7and8, gripping member100includes a compliant surface102positioned at least near an end of gripping member100extending away from frame94, which compliant surface102faces a corresponding surface of gripping member98. In one embodiment, compliant surface102may extend along the entire length of gripping member100. As shown, gripping member100extends generally perpendicularly to a flange103that is secured to a pair of blocks142at one end of a respective linkage140(only one block142and linkage140is shown inFIG.7). Each block142is slidably movable in a horizontal movement direction86along a corresponding guide rod assembly144secured to frame94. The other end of each linkage140is movably secured to an end152of a rod of a corresponding actuator138(FIG.8) operably connected to frame94. Each rod of actuator138is oriented generally parallel to a guide rod143of a corresponding guide rod assembly144(FIG.7). In response to the rod end152of each actuator138being urged into movement relative to the body of actuator138by controller76(FIG.5), linkage140is similarly urged into movement along horizontal movement direction86. For example, with gripping members98,100positioned side-by-side at substantially the same vertical position relative to one another and at least partially laterally surrounding an article row148(FIG.14), in response to rod ends152being actuated in one direction, gripping member100is similarly urged toward gripping member98(FIG.15), resulting in gripping members98,100applying a compressive force to the article array, such as article array148(FIG.15) positioned between gripping members98,100. Compliant surface102of gripping member100in combination with the facing surface of gripping member98helps maintain a sufficient frictional force therebetween, permitting the article row to be transported between different locations. Conversely, in response to rod ends152being actuated in the other direction, gripping member100is sufficiently urged away from gripping member98(FIG.17), resulting in removal of the compressive force applied by gripping members98,100to the article array, such as article array A (FIG.17) positioned between gripping members98,100. In summary, vertical movement direction84, which corresponds to the movement direction of gripping member98, and horizontal movement direction86, which corresponds to the movement direction of gripping member100, are perpendicular to one another, which will be discussed with regard to article row manipulation in further detail below.

As further shown inFIGS.6-7, a plurality of cover handling devices146are secured to corresponding support structures154,156that are secured to frame94. Cover handling devices146are shown in a retracted position. Cover handling devices146, which include respective actuators160, such as a pneumatic actuators, further include suction members158secured to corresponding ends of the actuators. In order to pick up a covering such as a tray or slip sheet18(FIG.5), robot74(FIG.5) positions head90vertically above the appropriate covering storage area such as covering storage area19(FIG.5). Suction members158of the cover handling devices146are urged toward an extended position162(FIG.7) that is in contact with the tray or slip sheet18. As a result of applying a suction pressure by each suction member158, the tray or slip sheet18is secured to the suction members158for placement over a pallet or article array at stacking area72(FIG.5).

As further collectively shown inFIGS.6-8, a cover handling device136such as for moving a covering such as a top frame20(FIG.1) is now discussed. Cover handling device136includes a pair of actuators122, such as pneumatic actuators having opposed ends124,126. Ends124are pivotably connected to a support structure120that is secured to frame94. Ends126are each pivotably connected to a crank132that is pivotably connected to rotate about an axis130of a corresponding rotational guide assembly128secured to frame94. Crank132extends to an engagement feature134. In order to pick up a top frame20(FIG.5), robot74(FIG.5) positions head90vertically above the appropriate covering storage area such as covering storage area21(FIG.5). In response to increasing the distance between opposed ends124,126of actuator122, crank132is urged into sufficient rotational movement about axis130such that each engagement feature134engages top frame20as depicted inFIG.8for placement over a pallet or article array at stacking area72(FIG.5).

As a result of the novel features of the article handling head90(FIG.5) previously discussed being incorporated into palletizing cell70(FIG.5), article rows14(e.g., rows A-N ofFIG.3A) (FIG.2) can be efficiently constructed, forming article arrays16(FIG.1), and by continuing to form additional article arrays16, palletized articles10(FIG.1) may be constructed. In addition, by virtue of unique features of gripping members98,100, the same article handling head90may accommodate differently sized articles14,15(seeFIGS.2and2A) wherein at least one of the height22, width24and length26of article14is different from the height23, width25and length27of article15, as well as permitting different article array arrangements, such as nested arrangement48(FIG.3A), non-nested closely spaced arrangement54(FIG.4A), and non-nested non-closely spaced arrangement (FIG.4C). For example, in combination with elongate gripping members98,100which selectably apply a sufficient compressive force to compressibly grip an article row for transporting the article row between different locations, the guide rod assembly144(FIG.7) is movable by actuator138along an extended length, capable of accommodating articles having a considerable range of sizes. When the actuator138, such as a pneumatic actuator applies substantially the same closing force or compressive force anywhere along guide rod assembly, which force being sufficient to compressively grip the article row for transport, but not sufficient to deform or damage the article row, the article handling head of the present invention can accommodate, without modification or change out, a vast majority of the range of sizes of articles suitable for palletizing. Optionally, for thicker or heavier articles, as well as thinner articles, the operator interface may include a weight parameter that could change the magnitude of compressive force to accommodate such article rows.

Each rod of actuator138is oriented generally parallel to a guide rod143of a corresponding guide rod assembly144(FIG.7). In response to the rod end152of each actuator138being urged into movement relative to the body of actuator138by controller76(FIG.5), linkage140is similarly urged into movement along horizontal movement direction86.

Moreover, as a result of operator interface77(FIG.5) of controller76(FIG.5), the operator has automated article row processing options not previously available. For example, in one embodiment, an operator (not shown) may be provided with an opportunity to input multiple parameters relating to the construction of palletized articles comprised of article arrays44(FIG.3A), each article array having a plurality of article rows A through N comprised of first articles14(FIG.2) extending in one of an x-direction and a y-direction within a rectangular areal footprint in the x-direction and the y-direction, having the x-dimension and the y-dimension of a covering or slip sheet18comprising: inputting parameters including a height dimension22, a width dimension24and a length dimension26of a first article14(FIG.2), a dimension28of the rectangular areal footprint (seeFIG.3A) in the x-direction, a dimension30of the rectangular areal footprint in the y-direction, a dimension of a width of article rows44to be provided from an article row source68(FIG.5), a type of arrangement, such as nested arrangement48(FIG.3A), non-nested closely spaced arrangement54(FIG.4A) and non-nested non-closely spaced arrangement58(FIG.4C) to be used between adjacent article rows (A through N) for building the first article arrays44, and the direction (x-direction or y-direction) and length dimension (respective dimensions28,30) of the article rows (A through N). In response to the parameters being input, controller76(FIG.5) controls a number of articles contained in a first row (e.g., row A) of first articles14, and each subsequent row of first articles14. That is, once the parameter have been input by the operator, the controller76, in a known manner, executes software source code or an alogorithm directed to calculating the maximum numbers of article rows and the numbers of articles in each article row, including edge spacing, as well as the gaps/overlaps between adjacent rows, depending upon the type of arrangement selected by the operator.

The operation of the robotic palletizing cell70(FIG.5) which manipulates articles to ultimately form a palletized article is now further discussed. As shown inFIG.9, articles14received from article row source68are provided along article conveyor78and monitored by a sensor group150controlled by a controller76(FIG.5) such as by counting the number of articles14breaking a beam (not shown) directed transverse to the direction of articles moving along article conveyor78and selectively interrupting the flow of articles14, resulting in the formation of an article row148at collection area80containing a predetermined or controlled number of articles14, from controller76calculations based from the operator-entered parameters previously discussed. A more detailed discussion of the operations relating to the article conveyor and collection area is contained in Applicant's U.S. Pat. No. 7,634,894 titled “System And Method For Palletizing Articles” and co-pending U.S. patent application Ser. No. 15/410,317 titled “System And Method For Forming And Moving An Article Array” which are each hereby incorporated by reference in their entirety.

Once article row148is collected at and supported by a horizontal surface of collection area80, as shown inFIGS.10and14, robot74positions head90such that the pair96of gripping members98,100at least partially laterally surround article row148. As appreciated by one having ordinary skill in the art, gripping members98,100are sized to accommodate or at least partially laterally surround each article of an article row containing the maximum number of articles required to form an article array, such as shown in row A of article array44ofFIG.3A. Of course, as shown inFIG.11, gripping members98,100are also sized to accommodate for (at least partially laterally surrounding) (FIG.14)) each article of an article row containing less than the maximum number of articles required, such as article row150(FIG.11) shown supported by the horizontal surface of collection area80.

Once gripping members98,100, as shown inFIG.14have at least partially laterally surrounded article row148at collection area80, then as further shown inFIG.15, as a result of actuation of actuator138, gripping member100is urged in a direction parallel to the horizontal support surface of collection area80toward gripping member98, applying a compressive force to opposed laterally surrounded surfaces of article row148. A frictional force between gripping members98,100and the corresponding facing surfaces of the article row are sufficient to permit head90(FIG.6) to transport article row148away from collection area80.

For purposes of clarity and brevity, article rows formed on and supported by collection area80will continue to be identified as article row148, with the article rows148transported from collection area80being re-identified upon being moved to, placed on, and supported by the horizontal surface of stacking area72of the robotic palletizing cell70(FIG.5). Therefore, as collectively shown inFIGS.5and16and17, article148becomes article row A (e.g.,FIG.3A) when transported from collection area80to stacking area72. The article rows positioned at stacking area72, as shown inFIG.3A, extend in the x-direction, which would have previously been selectively input by the operator as previously discussed. As shown inFIG.16, row A is positioned on and supported by stacking area72. Upon row A being positioned on stacking area72, as further shown inFIG.17, gripping members98,100are moved away from one another sufficiently to remove the compressive force applied to row A, as previously discussed. Once the compressive force applied to row A has been removed, head90is returned to collection area80such that gripping members98,100at least partially laterally surround a subsequently formed article row148as shown inFIGS.9and14, followed by gripping members98,100applying a compressive force to article row148as shown inFIG.15, as previously discussed. In a manner as previously discussed and as shown inFIG.18, the subsequently formed article row148becomes row B upon being transported from collection area80and being positioned in close proximity to row A at stacking area72, with gripping member98positioned between adjacent rows A, B. Once gripping member98is positioned between adjacent rows A, B as shown inFIG.18, as further shown inFIG.19, gripping members98,100are moved away from one another sufficiently to remove the compressive force applied to row B, as previously discussed.

Once rows A, B are arranged as shown inFIG.19, depending upon which article row arrangement was selected by the operator, i.e., nested arrangement48(FIG.3A), non-nested closely spaced arrangement54(FIG.4A), or non-nested non-closely spaced arrangement58(FIG.4C), different movements by gripping members98,100may occur. For example, if the operator had selected nested arrangement48(FIG.3A) or non-nested closely spaced arrangement54(FIG.4A), then as shown inFIG.20, gripping member98is raised in a direction, such as a vertical direction that is perpendicular to and away from the support surface of stacking area72. However, if the operator had selected non-nested non-closely spaced arrangement58(FIG.4C), raising gripping member98in a vertical direction that is perpendicular to and away from the support surface of stacking area72, as shown inFIG.20is optional, prior to head90being returned to collection area80such that gripping members98,100at least partially laterally surround a subsequently formed article row148as shown inFIGS.9and14, followed by gripping members98,100applying a compressive force to article row148as shown inFIG.15, as previously discussed.

Once gripping member98is raised in a direction, such as a vertical direction that is perpendicular to and away from the support surface of stacking area72as shown inFIG.20, and if the operator had selected nested arrangement48(FIG.3A) or non-nested closely spaced arrangement54(FIG.4A), then as shown inFIG.21(for nested arrangement48), head90is moved in a lateral direction parallel to stacking area72such that gripping member100of the pair of gripping members urges row B into a nested arrangement relative to row A, or as shown inFIG.22(for non-nested closely spaced arrangement54), head90is moved in a lateral direction parallel to stacking area72such that gripping member100of the pair of gripping members urges row B toward row A, but not in a nested arrangement (e.g., rows A and B in contact with each other, or at least separated by a gap that is less than the thickness of gripping member98). However, if the operator had selected non-nested non-closely spaced arrangement58, and gripping members98,100and rows A, B are positioned as shown inFIG.20, moving head90in a lateral direction parallel to stacking area72such that gripping member100of the pair of gripping members urges row B sufficiently into a nested arrangement relative to row A (FIG.21) or a non-nested arrangement (FIG.22) is optional.

Irrespective of head90and rows A, B being arranged as shown in one ofFIG.20,21or22(depending upon which of arrangements48,54,58applies, as previously discussed) head90is returned to collection area80such that gripping members98,100at least partially laterally surround a subsequently formed article row148as shown inFIGS.9and14, followed by gripping members98,100applying a compressive force to article row148as shown inFIG.15, as previously discussed. In a manner as previously discussed and as shown inFIG.23, the subsequently formed article row148becomes row C upon being transported from collection area80and being positioned in close proximity to row B at stacking area72, with gripping member98positioned between adjacent rows B, C. Once gripping member98is positioned between adjacent rows B, C as shown inFIG.23, as further shown inFIG.24, gripping members98,100are moved away from one another sufficiently to remove the compressive force applied to row C, as previously discussed.

Once rows A, B, C are arranged as shown inFIG.24, depending upon which article row arrangement was selected by the operator, i.e., nested arrangement48(FIG.3A), non-nested closely spaced arrangement54(FIG.4A), or non-nested non-closely spaced arrangement58(FIG.4C), different movements by gripping members98,100may occur. For example, if the operator had selected nested arrangement48(FIG.3A) or non-nested closely spaced arrangement54(FIG.4A), then as shown inFIG.25, gripping member98is raised in a direction, such as a vertical direction that is perpendicular to and away from the support surface of stacking area72. However, if the operator had selected non-nested non-closely spaced arrangement58(FIG.4C), raising gripping member98in a vertical direction that is perpendicular to and away from the support surface of stacking area72, as shown inFIG.25is optional, prior to head90being returned to collection area80such that gripping members98,100at least partially laterally surround a subsequently formed article row148as shown inFIGS.9and14, followed by gripping members98,100applying a compressive force to article row148as shown inFIG.15, as previously discussed.

Once gripping member98is raised in a direction, such as a vertical direction that is perpendicular to and away from the support surface of stacking area72as shown inFIG.25, and if the operator had selected nested arrangement48(FIG.3A) or non-nested closely spaced arrangement54(FIG.4A), then as shown inFIG.26(for nested arrangement48), head90is moved in a lateral direction parallel to stacking area72such that gripping member100of the pair of gripping members urges row C into a nested arrangement relative to rows A, B, or as shown inFIG.26A(for non-nested closely spaced arrangement54), head90is moved in a lateral direction parallel to stacking area72such that gripping member100of the pair of gripping members urges row C toward row B, but not in a nested arrangement (e.g., rows B and C in contact with each other, or at least separated by a gap that is less than the thickness of gripping member98). However, if the operator had selected non-nested non-closely spaced arrangement58, and gripping members98,100and rows A, B, C are positioned as shown inFIG.25, moving head90in a lateral direction parallel to stacking area72such that gripping member100of the pair of gripping members urges row C sufficiently toward rows A, B into a non-nested arrangement relative to rows A, B (FIG.26A) is optional.

FIGS.12-13show head90during construction of a partial article array82, with the article rows (e.g., rows A, B, C fully shown) extending in the y-direction (FIG.12) and the x-direction (FIG.13).

It is to be understood that the above steps for rows A-C are repeated for chronologically increasing article rows through row N, in which the arrangement and construction ofFIGS.28-30as it relates to rows N−1, N correspond to the arrangement and construction of FIGS. A, B. For purposes of brevity the construction of additional article rows is not repeated. Once row N has been placed in the manner disclosed in the present invention, the full article array44has been constructed.

Once article array44has been constructed, head90utilizes cover handling device146in a manner previously discussed and partially shown inFIG.18to move head90to pick up a covering18, such as a slip sheet or tray to be overlain over completed article array44, such as shown inFIG.1for palletized article10(FIG.1).

Once covering18has been applied over article array44, article array46(FIG.3D) having rows N+1 through 2N is constructed, the construction of which article array46concluding withFIGS.31-33(and all subsequent article rows) is essentially the same as constructing article array44and for purposes of brevity are not repeated herein.

Once all article rows have been constructed, head90utilizes covering handling device136(FIG.8) for picking up and placing a covering, such as one of a top sheet and a tray or a top frame17(FIG.1) over the article row, thereby constructing a palletized article.

In one embodiment, article conveyor78may include a second collection area164. In one embodiment, the palletizing cell may include a second article conveyor166having a collection area168that is provided articles from an article row source170.

It is to be understood that the article handling head which is usable for building an article array from rows of first articles, each first article having a first height, a first width, and a first length, is also usable, without requiring a change-out of or modification of components of the head, for building an article array from rows of second articles, with each second article having a second height, a second width, and a second length, wherein at least one of the second height, the second width, and the second length of the second articles is different from the first height, the first width, and the first length of the first articles.

In one embodiment, the operator may also be provided with an opportunity to input a height of the palletized articles that is different from the maximum height, if desired.

In one embodiment, instead of the operator being prompted to input all parameters, such as the article array arrangement, or direction of the article rows, the operator may be prompted to input fewer parameters, such as the size parameters of the article to be processed into a palletized article.