Abstract:
A device for engaging and aligning items moving along a conveyance line that are to be positioned on a pallet is provided. The device includes a robotic arm positioned adjacent the conveyance line and having a manipulator thereon. The manipulator includes a number of fingers that extend downwardly from the manipulator in order to engage the items on the conveyance line. The fingers operate to stop and align the items to form a well-defined stack in the shape defined by the position of the fingers on the manipulator. The manipulator can rotate while the fingers are in engagement with the stack of items in order to reposition the items as desired for placement on the pallet by sliding the items along the various surfaces of the system and without lifting the items off of the conveyance line, thereby limiting the cost and time associated with the operation of the device.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from U.S. Provisional Application Ser. No. 61/596,850, filed on Feb. 9, 2012, the entirety of which is expressly incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally mechanisms for positioning and stacking goods, items or packages for shipment, and more particularly to a device, mechanism or machine that operates to receive a number of different types and sizes of items in order to reposition and place the items in layers on a pallet. 
     BACKGROUND OF THE INVENTION 
     There are many types of machines that have been used for the purpose of re-orienting placing goods in the proper location for the shipment of the goods, such as in layers on a pallet. In these configurations, the goods can be readily prepared for shipment in a conventional manner. 
     However, due to the variety of configurations of the goods and packaging for the goods to be positioned on the pallets for shipment, one significant issue in performing this function is properly aligning the goods/packages in the appropriate layers in order to effectively form the pallet. A number of other considerations, such as the weight of the goods in the packages, the number of packages to be placed on the pallet, etc., are also taken into account when determining where and in what arrangement to properly locate the packages in the pallet. 
     With prior art machines of this type, the primary function of the machine is to determine the type of good/package, to orient the good/package in the proper manner, and the move the good/package into the proper position on the pallet. When a completed layer of the goods/packages is completed on the pallet, the machine can further lower the pallet in order to position the pallet in a position where it can accept another layer of the goods/packages thereon, or, if full, the pallet can be moved from the machine for further processing prior to shipment, with an empty pallet being substituted in its place to receive additional goods/packages. 
     The goods/packages are moved towards the machine in any conventional manner, such as on a conveyor belt, to maintain the flow of the goods/packages as desired. Upon reaching the machine, the goods/packages are positioned in the desired configuration by the machine in order to enable the goods/packages to be ready for placement on the pallet. 
     In prior art machines that perform this function, the orientation of the goods/packages is accomplished by a variety of devices placed in the path of the packages as they move to a palletizing station of the machine. One example of these types of devices is formed as a conveyor having shiftable barrier components thereon which can be moved into various positions over the conveyor belt to deflect the incoming packages into a desired position in conjunction with the side rails positioned on either side of the conveyor. 
     Other devices include frames having one or movable portions on which is disposed a head having a number of suction or other grippers attached to the head. The grippers operate to grab each package and lift and rotate the package into the desired position. Once in that position, the head is moved over the pallet and subsequently lowered to position the package where desired on the pallet. 
     While these devices are capable of moving packages into desired positions to form layers of the packages or items in forming pallets of the items for shipment, the devices require many separate structural items separate from the actual items or package conveyance line, which greatly increases the complexity and cost of the devices. 
     In addition, while the movable barrier components or grippers can effectively move most of the types of items which are being stacked on a pallet, the weight of the items can create issues with each of these types of device. For items that are relatively lightweight, they can bounce off of the movable barriers into orientations that cannot be readily stacked. Conversely, for items that a relatively heavy, the suction or gripper head cannot effectively lift the heavy item into the proper orientation and location. 
     Further, most of the prior art devices are constructed and operate in a manner that when the device is inoperable for some reason, the conveyance line for palletizing the items or packages cannot be run until the device is made operable once again. Further, the prior art devices do not include structures that are readily capable of engaging and straightening or aligning a stack of sheets with one another as that stack is also moved by the device into the desired position. 
     Thus, it is desirable to develop a device that can operate to position items and packages, such as boxes or stacks of sheets of material, for example, in a desired position in a number of layers to form a pallet that can rotate the items into the desired position for forming a layer on a pallet. It is also desirable to develop a device that can accomplish this function with existing conveyance lines but without impairing the operation of the line when the device is not operating. It is still also desirable to develop a device that is able to align and reposition the items without having the weight of the items affect the operation of the device or the need for lifting the items above the surface of the conveyance line. 
     SUMMARY OF THE INVENTION 
     Briefly described, one aspect of the present disclosure provides a device for engaging and aligning items moving along a conveyance line that are to be positioned on a pallet. The device includes a robotic arm positioned adjacent the conveyance line and having a head, manipulator or gripper thereon. The manipulator includes a number of fingers that extend downwardly from the head in order to engage the items on the conveyance line. The fingers operate to stop and align the items to form a well-defined stack in the shape defined by the position of the fingers on the manipulator. 
     According to another aspect of the present disclosure, the manipulator can also rotate while the fingers are in engagement with the items in order to reposition the items as desired. This is done by sliding the items along the various surfaces of the system and without lifting the items off of the conveyance line, thereby limiting the cost and time associated with the operation of the device. 
     According to still another aspect of the present disclosure, the robotic arm and manipulator form a self contained unit that can be positioned immediately adjacent one side of an existing conveyance line to be utilized with the line. In this configuration, when the arm is inoperable for any reason, the arm can be manually repositioned away from the conveyor such that the conveyance line can still be operated manually without interference from the robotic arm and manipulator. 
     Numerous other aspects, features, and advantages of the present disclosure will be made apparent from the following detailed description together with the drawings figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings illustrate the best mode currently contemplated of practicing the present invention. 
       In the drawings: 
         FIG. 1  is an isometric view of a one embodiment of a device constructed according to the present disclosure; 
         FIG. 2  is a left side elevation view of the device of  FIG. 1 ; 
         FIG. 3  is a front elevation view of the device of  FIG. 1 ; 
         FIG. 4  is a top plan view of the device of  FIG. 1 ; 
         FIG. 5  is an isometric view of the device of  FIG. 1  in a start position; 
         FIG. 6  is an isometric view of the device of  FIG. 1  initially engaging an item; 
         FIG. 7  is an isometric view of the device of  FIG. 1  moving a pallet onto a loading conveyor; 
         FIG. 8  is an isometric view of the device of  FIG. 1  elevating the loading conveyor to a loading position; 
         FIG. 9  is an isometric view of the device of  FIG. 1  moving a barrier adjacent the pallet and an item onto the pallet; 
         FIGS. 10A-10F  are isometric views of the device of  FIG. 1  moving additional items onto the pallet to form an item layer on the pallet; 
         FIG. 11  is an isometric view of the manipulator of  FIG. 1  grasping a separating sheet; 
         FIG. 12  is an isometric view of the device of  FIG. 1  placing the separating sheet over the item layer; 
         FIGS. 13A-13I  are isometric views of the device of  FIG. 1  lowering the loading conveyor to a secondary loading position and moving additional items onto the pallet to form another item layer on the pallet; and 
         FIG. 14  is an isometric view of the device of  FIG. 1  operating the loading conveyor to move the completed pallet. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now in detail to the drawing figures, wherein like reference numerals represent like parts throughout the several views, a palletizing system  10  includes an incoming feed conveyor, illustrated generally at  120  in  FIG. 1 . As best shown in  FIGS. 1-4 , the feed conveyor  120  is constructed in any suitable manner and operates to move stacks or bundles of items  100  towards a palletizing station  125 . The palletizing station  125  includes a loading conveyor  150  disposed immediately adjacent the feed conveyor  120  and an outfeed conveyor  130  extending away from the station  125 . In the palletizing station  125 , items  100  being palletized are positioned in a manner that enables the items  100  to form a layer  200  on a pallet, dunnage sheet, or similar member  170  that is arranged in conjunction with a number of additional layers  202  on the pallet  170 . The pallet  170  is supplied to the loading conveyor  150  of the palletizing section  125  from a supply stack  160  by a feeder system  190  that is disposed adjacent the section  125 , and in the illustrated embodiment, that is disposed generally opposite the outfeed conveyor  130 . 
     The loading conveyor  150  is formed with a frame  300  that supports a vertically movable conveyor section  310  therein. The range of motion of the conveyor section  310  extends from an upper position where the conveyor section  310  is aligned with the feed conveyor  120  to a lower position where the conveyor section  310  is aligned with the outfeed conveyor  130 . 
     In the lower position, the conveyor section  310  is also aligned with the feeder system  190 , such that replacement pallets  170  can be discharged onto the conveyor section  310  from the discharge conveyor and roller  110  of the feeder system  190  that is positioned beneath the frame  300 . The pallets  170  are placed on the conveyor  110  by a suitable mechanism  500  utilized by the system  190 . 
     The loading conveyor  150  additionally includes a movable barrier  320  secured to the frame  300 . The barrier  320  is slidably and optionally pivotally movable over the conveyor section  310  along a track  335  formed on the upper end of the frame  300  in order to enable the barrier  320  to form a back stop for the items  100  being positioned on the pallet  170 . 
     The frame  300  of the loading conveyor  150  also includes an upper surface  330  on which is disposed a supply of tie sheets  180 . When a layer  200  of items  100  has been formed on the pallet  170 , a tie sheet  180  can be moved from the upper surface  330  onto the top of the layer  200 . Additional items  100  can subsequently be positioned on the tie sheet  180  to form another layer  202  of items  100  on the pallet  170 . 
     Disposed adjacent the feed conveyor  120  and the loading conveyor  150  is disposed a riser  405  secured to the floor on which the system  10  is supported by a number of suitable fasteners (not shown). The riser  405  houses a power source (not shown) for a robotic arm  220  disposed on the top of the riser  405 . The arm  220  includes a base  400  secured to the riser  405 , a lower portion  410  rotatably secured to the base  400 , a central portion  420  rotatably connected to the lower portion  410  opposite the base  400 , and a distal portion  430  rotatably connected to the central portion  420  opposite the lower portion  410 . Each portion  410 ,  420  and  430  is controlled by suitable motors  440  operably connected to the respective portions  410 ,  420  and  430 . The motors  440  can be any suitable type of motor, such as a computer-programmable and controllable servo motor, that enables the arm  220  to be precisely moved relative to the items  100  and the other components of the system  10 . In addition, connections between the various portions  400 ,  410 ,  420  and  430  of the arm  220  enable the portions  400 ,  410 ,  420  and  430  to rotate with respect to one another through at least one hundred and eighty degrees)(180°) of motion, and more preferably at least two hundred and seventy degrees)(270°) of motion, and most preferably up to three hundred and sixty degrees (360°) of motion. In this manner, the arm  220  can be operated to align and move items  100  having virtually any configuration from the feed conveyor  120  onto the loading conveyor  150  to form layers on the pallet  170  in any desired shape. 
     The end of the distal portion  430  opposite the central portion  420  includes a manipulator  210 . The manipulator  210  includes a body  450  shaped to be complementary to the items  100  being stacked on the pallet  170 . While the body  450  can have any desired shape, in the illustrated embodiment, the body  450  has a generally triangular shape in order to conform to the shape of the items  100  engaged by the manipulator  210 . The body  450  is operably connected to the distal portion  430  of the arm  220  to be rotatable thereto. A motor  440  operably connected to the body  450  enables the body to rotate a full three hundred and sixty degrees (360°) relative to the distal portion  430 . 
     Depending from the body  450  are a number of fingers  460  secured at one end to the body  450 . The fingers  460  are shaped as a desired and formed from any suitable material and to be able to engage the items  100  coming along the feed conveyor  120 , and to align the items  100  on the conveyor  120 , thereby ensuring that the item  100  is in proper position for placement on the pallet  170 . To assist in performing this function, the fingers  460  can be formed of a generally rigid material, such as a hard plastic, that allows for some flexibility of the fingers  460 , but that also contacts the items  100  with sufficient force to align the items  100  as desired. Further, while a pair of fingers  460  are shown extending outwardly from the body  450  in the illustrated embodiment, any number, including one or more fingers  460 , or configuration of fingers  460  can be attached to the body  450  to provide the desired function. Also, the body  450  can include slots  475  thereon to enable the fingers  460  to be adjustably mounted to the body  450  where desired, or to enable different configurations for the fingers  460  on the body  450 . 
     The fingers  460  are formed in the illustrated embodiment to exclusively frictionally engage the items  100 , without any additional engagement means, such as suction means. Additionally, the fingers  460  in the illustrated embodiment engage only the sides of the items  100 , with no engagement of the fingers  460  with the top or bottom surfaces of the items  100 , such that the fingers  460  do not provide any lifting forces on the items  100 . Further, in the illustrated embodiment, the fingers  460  have a length sufficient to position the body  450  above the top surface of the items  100  when the fingers  460  are engaged with the items  100 . The fingers  460  can contact the feed conveyor  120  to ensure contact with the entirety of the item  100 , while keeping the body  450  from contacting the item  100  and potentially shifting the item  120  partially or totally out of engagement with the fingers  460 . 
     Referring now to  FIG. 5 , in operation, initially the system  10  is configured with the conveyor section  310  in the upper position and the barrier  320  moved to a retracted position, generally opposite the feed conveyor  120 . In  FIG. 6 , when the items  100  move toward the loading conveyor  150  along the feed conveyor  120 , the robotic arm  220  is moved to position the manipulator  210  over the first item  100  on the conveyor  120 . In  FIG. 7 , either subsequently or simultaneously with the movement of the manipulator  210  relative to the first item  100 , the conveyor section  310  is lowered to the lower position, where the pallet  170  or similar object is moved from the stack  160  by a suitable device  500  onto the conveyor  110 , which then discharges the pallet  170  onto the conveyor section  150 . The conveyor section  310  and the pallet  170  are then elevated to the upper position aligned with the feed conveyor  120 , as shown in  FIG. 8 . 
     Looking now at  FIG. 9 , once the conveyer section  310  is in the upper position, the barrier  320  is moved along the track  325  in the frame  300  to the desired position, which is determined by the size of the pallet  170  disposed on the conveyor section  310 . The barrier  320  essentially forms a back stop at the edge of the pallet  170 , ensuring that the items  100  are properly positioned over the pallet  170  in the desired configuration. 
     The robotic arm  220  and the manipulator  210  are then operated by controlling the motors  440  as desired to move the arm  220  to engage the fingers  460  with the item  100 . In engaging the item  100 , the fingers  460  are positioned against the item  100  such that the lateral movement of the body  450  and fingers  460  of the manipulator  210  can consequently laterally move the item  100 . From this position, the arm  220  and manipulator  210  are moved by the motors  440  to slide the item off of the feed conveyor  120  and onto the pallet  170  on the conveyor section  150 . As the item  100  is slid by the motion of the arm  220 , the manipulator  210  can simultaneously be rotated with respect to the distal portion  430  of the arm  220  in order to enable the fingers  460  to rotate the item  100  into the desired position for placement on the pallet  170 . The movement of the manipulator  210  can shift the position of the item  100  throughout the entire 360° rotational capacity of the manipulator  210 , such that the item  100  can be positioned as desired. 
     Further, in situations where the item  100  is formed of a stack of sheet of a material, the fingers  460  can additionally operate to stop the movement of the items  100  on the feed conveyor  120  and to align the sheets forming the item  100  into a vertical stack. Once aligned by the fingers  460  in this manner, the manipulator  210  can be moved from over the feed conveyor  120  to over the conveyor section  310  of the loading conveyor  150 , while the fingers  460  operate to maintain the alignment of the item  100  so that no sheets from the stack are left behind when the stack is being moved. 
     Referring now to  FIGS. 10A-10F , this process is shown being repeated in order to utilize the arm  220  and manipulator  210  to position a number of items  100  on the pallet  170  to form a first layer  500  on the pallet  170 . Once the first layer  200  is complete, as shown in  FIG. 11A , the arm  220  is moved to position a gripper  470  extending outwardly from the body  450  adjacent the stack of tie sheets  180 . The gripper  470  can operate via the motor  440  on the body  450  in a conventional manner to grasp an individual tie sheet  180  and move the sheet  180  by movement of the arm  220  and manipulator  210  to a position on top of the first layer  200 , as shown in  FIG. 11B . 
     Once the tie sheet  180  has been placed on top of the first layer  200 , the conveyor section  310  is lowered to position the tie sheet  180  at a position that is aligned with the feed conveyor  120 , as shown in  FIG. 13A . In this position, additional items  100  can be moved onto the tie sheet  180  over the first layer  200  by the arm  220  and manipulator  210  to form a second layer  202 , as shown in  FIGS. 13B-13I . 
     Once completed, the pallet  170  including the first layer  200  and second layer  502  can be moved onto the outfeed conveyor  130  by operating the conveyor section  310 , as shown in  FIG. 14 . At this point, a new pallet  170  can be discharged onto the conveyor section  310 , and the process for forming new layers  200  and  202  thereon can be restarted. 
     The movement of the item  100  by the manipulator  210  off of the feed conveyor  120  and onto the conveyor section  310  of the loading conveyor  150  only slides the item  100  along the various surfaces of the conveyors  120  and  150 , such that the design of the manipulator  210  can be simplified from prior art grippers required to lift the item(s) being moved. Further, the weight of the items  100  being moved also is less of an issue as a result of the lack of vertical movement of the item  100  caused by the arm  220  and manipulator  210 . 
     Additionally, due to the positioning of the riser  405  and arm  220  to one side of the conveyors  120  and  150 , in the situation where the arm  220  breaks down for some reason and is inoperable, the arm  220  can be moved away from the conveyors  120  and  150  to enable the operation of the loading conveyor  150  in a more conventional manner. This enables the arm  220  to be utilized with existing palletizing system without the need for making significant expenditures and/or alterations to the existing systems. 
     In other alternative embodiments of the invention, the operation of the arm  220  and the loading conveyor  150  are controlled by a central controller (not shown) which effectively synchronizes their operation to maximize the effectiveness of the overall system  10  including the arm  220  and the loading conveyor  150 . 
     Also, one or more portions of the conveyors  120 ,  130  and  150  in the system  10  can be formed with breakaway parts (not shown) that function to enable the items  100  coming down the feed conveyor  120  to damage to the system  10 . 
     Further, in addition to having the conveyor section  310  of the loading conveyor  150  be movable, the loading conveyor  150  can alternatively employ other suitable manners of positioning the assembled layers  200  directly on the pallet  170 . For example, the loading conveyor  150  can employ a moveable platform (not shown) that extends outwardly from the frame  300  over the conveyor section  310  and is aligned with the feed conveyor  120 . Once a layer  200  of the items  100  has been formed on the platform by the arm  220  and manipulator  210 , the platform can be moved to enable the layer  200  to drop downwardly onto either the pallet  170  or onto a layer  200  already present on the pallet  170 . Once the layer  200  is located on the pallet  170 , the pallet  24  can be lowered by lowering the conveyor section  310 , such that the platform can be repositioned over the pallet  170  and adjacent the feed conveyor  120  to enable a subsequent layer  202  to be formed for placement on the pallet  170 . 
     Various other embodiments of the present disclosure are contemplated as being within the scope of the filed claims particularly pointing out and distinctly claiming the subject matter regarded as the invention.