Patent Description:
This invention relates generally to apparatus and methods for feeding a new slug of carton blanks to a carton blank magazine in a cartoning line. More particularly, this invention relates to an automatic apparatus and methods for feeding slugs of carton blanks to a magazine of carton blanks in a cartoning line.

Folded carton blanks are frequently delivered to packaging machinery in large quantities (e.g., <NUM> or more cartons) in an open-top master case or banded bundle. The cartons blanks in these master cases are typically emptied onto a horizontal magazine by either a machine operator or by automated means. The horizontal magazine may be operably disposed in a cartoning line where carton blanks are fed from the magazine to a cartoning machine which feeds or picks the blanks from such a magazine, erects cartons from the blanks, fills and sends the cartons with product and discharges the filled cartons. In any event, when a master case is emptied onto the magazine by a machine operator, the process often involves inverting the master case and dumping the cartons onto a magazine, such as a horizontal magazine, removing the master case, and then patting and adjusting (i.e., "conditioning") the slug of carton blanks by hand to assume a uniform placement that will successfully be fed downstream to a cartoner. Automated methods of magazine loading can vary, but all must duplicate some aspects of the machine operator conditioning of the slug of carton blanks. Improper conditioning of the slug of carton blanks can result in miss-feeds or jams in the cartoner, or with problems on the magazine itself such as a trailing-most carton blank fall back or away from the line of other carton blanks in the horizontal magazine, or carton damage.

Previous automated efforts for placing a slug of carton blanks on horizontal magazines have typically involved placing the rectangular or square-shaped slug of carton blanks in a horizontal magazine by various means and then seeking to condition the group similar to how a machine operator would accomplish the tasks on the magazine. Placing the compressed rectangular or square-shaped slug on the horizontal magazine provided only limited possibilities for achieving a consistent desired shape of the slug of carton blanks on the magazine. Results would include carton group height variation from front to back, excessive gapping between placement groups, top and side carton shingling, trailing-most carton group fall-back, and marring and damage to cartons.

In view of the above, it is desirable to maintain a minimal accumulation of folded flat carton blanks or "prime" of carton blanks in the magazine to accommodate the demand for carton blanks at blank pick or carton erection stations just downstream of the blank magazine. The preferred orientation of carton blanks in the blank magazine is with the upper edges of each carton blank tilted forwardly respective to their lower edges which trail in the feed or machine direction. Thus, a desired shape of a slug of carton blanks being delivered to the magazine is a parallelogram, with the upper edges of each carton blank tilted forwardly respective to their lower edges. To this end, it is preferred to deliver a new slug of flat carton blanks to the last carton blank of the magazine so that the blanks in the slug lean forward, with the first blank in the slug engaging the last blank of the carton stack in the magazine. <CIT> and <CIT> discloses respective apparatus for feeding slugs of carton blanks to a carton blank magazine, according to the prior art.

When the last blank in a carton magazine is not disposed at the preferred lean angle, or inclination, with the stack, it might be tipped rearwardly so that it lies horizontally on the magazine floor, drive chains the like. When the new slug moves toward the magazine stack, this flat, out-of-position blank or fallen carton blank blocks consistent positioning of fresh blanks in the new slug of blanks and can jam the magazine replenishment operation desired. This could cause a line disruption or stoppage and waste, whether the new slug is machine fed or manually fed.

Accordingly, one aspect of the invention is to provide improved apparatus and methods for replenishing carton blanks in a carton magazine and eliminating difficulties arising from fallen or out-of-position carton blanks at the rear or upstream end of the blanks in a carton blank magazine.

A further aspect of the invention is to provide improved apparatus and methods for automatically replenishing carton blanks in a carton blank magazine while eliminating adverse effects of a fallen or out-of-position blank in the magazine.

The present invention overcomes the foregoing and other shortcomings and drawbacks of machinery for replenishing carton blanks in a carton magazine. While the present invention will be discussed in connection with certain embodiments, it will be understood that the present invention is not limited to the specific embodiments described herein.

According to one embodiment of the invention, a carton handling system for loading a carton blank magazine with a slug of carton blanks is provided. The carton handling system includes a carriage assembly with a carton handling tool. The carriage assembly is capable of moving the carton handling tool in two axes of motion to receive the slug of carton blanks and to position the slug of carton blanks in the carton blank magazine. The material handling system further includes a finger carried on the carton handling tool. In this regard, the carton handling tool is movable to engage the finger with an underside of a fallen carton blank lying at an end of an advancing stack of blanks in the carton blank magazine so as to lift the fallen carton blank against a preceding blank at the end of the advancing stack of blanks. The carton handling tool is also movable to position the slug of carton blanks at an endmost blank in the advancing stack of blanks. In an aspect of the invention, movement of the carton handling tool to receive the slug of carton blanks is in an upward direction relative to the carton blank magazine.

According to one aspect of the invention, the carton handling tool further includes a first compression jaw and a second compression jaw spaced apart from the first compression jaw along an operative end of the carton handling tool. At least one of the first and second compression jaws is operable to engage and to hold the slug of carton blanks such that the plurality of blanks are held against inclination prior to placement of the slug of carton blanks at the endmost blank in the advancing stack of blanks. In another aspect, the first compression jaw is operatively connected to a slide assembly configured to laterally move the first compression jaw toward or away from the second compression jaw. In one aspect, the first compression jaw is pivotable about the slide. In yet another aspect, the first compression jaw is pivoted in a direction away from the second compression jaw to position each carton blank of the slug of carton blanks at an inclination prior to placement of the slug of carton blanks at the endmost blank in the advancing stack of blanks.

According to yet another aspect of the invention, the second compression jaw is pivotably mounted on the carton handling tool. In one aspect, the first compression jaw and the second compression jaw are each pivoted in a direction toward the carton blank magazine to position each blank of the slug of carton blanks at an inclination prior to placement of the slug of carton blanks at the endmost blank in the advancing stack of blanks.

In one aspect of the invention, the finger is fixed to a front end of the carton handling tool. In another aspect, the finger is fixed to the slide assembly. In yet another aspect, the finger is fixed to the first compression jaw.

According to an aspect of the invention, the carriage assembly includes a first sensor positioned to detect the fallen carton blank at the end of the advancing stack of blanks in the carton blank magazine. In another aspect, the carriage assembly includes a second sensor positioned to detect the endmost blank in the advancing stack of blanks in the carton blank magazine.

According to one aspect of the invention, the carriage assembly is capable of simultaneously moving the carton handling tool along a vertical axis and a horizontal axis relative to the carton blank magazine, and is capable of moving the carton handling tool in a downward direction from the carton blank magazine along the vertical movement axis and in a rearward direction away from the carton blank magazine along the horizontal movement axis to retract the finger from a lifted fallen carton blank.

According to one embodiment of the invention, a method of loading a slug of carton blanks into a carton blank magazine is provided. The method includes providing a carton handling system having a carriage assembly including a carton handling tool. The carriage assembly is capable of moving the carton handling tool in two axes of motion to receive the slug of carton blanks and to position the slug of carton blanks in the carton blank magazine. The carton handling system further includes a finger carried on the carton handling tool and at least one sensor. The method includes receiving the slug of carton blanks by the carton handling tool, moving the slug of carton blanks toward an end of an advancing stack of blanks in the carton blank magazine, and detecting whether a fallen carton blank carton is lying at the end of the advancing stack of blanks. If a fallen carton blank is detected, lifting the fallen carton blank against a preceding blank carton at the end of the advancing stack of blanks with the finger, moving the slug of blanks toward the end of the advancing stack of blanks, and releasing the slug of blanks at the end of the advancing stack of blanks.

According to an aspect of the invention, the method includes moving the carton handling tool downwardly and rearwardly away from the stack of blanks in the carton blank magazine to release the slug of blanks to a position to receive another slug of blanks.

In another aspect of the invention, the method includes moving the carton handling tool rearwardly away from a lifted fallen carton blank and downwardly to a position to move the slug of blanks toward the end of the advancing stack of blanks in the carton blank magazine.

In yet another aspect of the invention, the carton handling tool further includes a first compression jaw and a second compression jaw with the first compression jaw being pivotably mounted on the carton handling tool. The step of moving the slug of blanks toward the end of the advancing stack of blanks further includes pivoting the first compression jaw to position the slug of carton blanks at an inclination prior to placement of the slug of carton blanks at the endmost blank in the advancing stack of blanks.

In another aspect of the invention, the first compression jaw is operatively connected to a slide assembly configured to laterally move the first compression jaw toward and away from the second compression jaw. The step of receiving the slug of carton blanks by the carton handling tool further includes moving the slide assembly to adjust a distance between the first compression jaw and the second compression jaw to receive the slug of carton blanks and moving the slide assembly to compress the slug of carton blanks between the first compression jaw and the second compression jaw.

In yet another aspect of the invention, the step of receiving the slug of carton blanks by the carton handling tool includes moving the carton handling tool in an upward direction relative to the carton blank magazine.

Various additional features and advantages of the invention will become more apparent to those of ordinary skill in the art upon review of the following detailed description of one or more illustrative embodiments taken in conjunction with the accompanying drawings.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the general description given above and the detailed description given below, serve to explain the one or more embodiments of the invention.

Aspects of the present invention are directed to a linear carton handling system and process for retrieving a slug of carton blanks, conditioning the slug of carton blanks, and placing the conditioned slug of carton blanks into a horizontal carton magazine for further processing. In this regard, embodiments of the carton handling system, otherwise referred to as a loader, are for use in machinery for automatically loading the horizontal carton magazine with carton blanks. The carton handling system of the present invention may be utilized as a component of an automatic magazine loader (AML) system which may include the material handling device, the carton handling system, the horizontal or extended carton magazine, an empty case conveyor, and an operator platform, for example.

The carton handling system is configured to automatically retrieve and extract a slug of carton blanks from the material handling device and place the slug of carton blanks onto the horizontal magazine at the end of an advancing stack of carton blanks in the magazine. At the same time, the carton handling system is configured to automatically condition the slug of carton blanks to provide the slug of carton blanks with a desired shape, or lean, prior to placing the slug of carton blanks on the horizontal magazine. Prior to placing the slug of carton blanks onto the horizontal magazine, the carton handling system is configured to correct any fallen carton blanks at the end of an advancing stack of carton blanks in the magazine. In this regard, the carton handling system includes a carton blank lifting finger and is configured to detect and upright a fallen carton blank with the finger prior to placing the conditioned slug of carton blanks at the end of the advancing stack of carton blanks in the magazine. Each of these aspects of the invention promote cartoning line efficiency and will be described in turn below.

By conditioning the slug of carton blanks, it is meant that the slug of carton blanks is manipulated, or conditioned, to have a desired parallelogram shape prior to being placed in the horizontal magazine. A conditioned slug of carton blanks will have the upper edges of each carton blank of the slug of carton blanks tilted forwardly respective to their lower edges which trail in the feed or machine direction. The side edges of the cartons are generally aligned to form smooth side surfaces of the slug of carton blanks. The tilt which gives the slug of carton blanks its parallelogram shape may be referred to as lean, inclination, or controlled lean, for example. As will be described in further detail below, controlled lean of the advancing stack of carton blanks in the horizontal magazine is needed so that carton blanks can be fed down a throat of the magazine without jamming or otherwise damaging the carton blanks.

Various carton blanks are depicted in the figures to illustrate aspects of the invention. Other carton blank formats (e.g., size and shape) can be handled by embodiments of the invention, and reference to specific carton blanks herein is not meant to limit the scope of the invention.

Referring now to the figures, <FIG> illustrates an exemplary AML system <NUM> in which a carton handling system <NUM> according to embodiments of the present invention has particular utility. The AML system <NUM> includes a case receiving station <NUM> and an in-feed conveyor <NUM> configured to receive and convey master cases <NUM> of carton blanks to a material handling device <NUM>. Each master case <NUM> includes a slug <NUM> of folded carton blanks <NUM> which may comprise <NUM> or more individual folded carton blanks <NUM>, for example. As shown, the individual carton blanks <NUM> are stored in a side-by-side arrangement that conforms to the shape of the case <NUM>. Thus, the slug <NUM> of carton blanks <NUM> is generally rectangular in shape.

The material handling device <NUM>, sometimes referred to herein as the case flipping station <NUM>, includes a two-axis of motion robotic device <NUM> having a pair of kinematic arm clamps <NUM>. The robotic material handling device <NUM> is configured to clamp, invert, and rotate each master case <NUM> to an accessible position over the carton handling system <NUM> so that the slug <NUM> of carton blanks <NUM> may be retrieved by a carton handling tool <NUM> of the carton handling system <NUM>. As described in further detail below, the carton handling tool <NUM> is configured to extend in an upward direction to the inverted master case <NUM>, grip and remove the slug <NUM> of carton blanks <NUM> from the master case <NUM>, and gently lower the slug <NUM> of carton blanks <NUM> down to a connect horizontal magazine <NUM>. The carton handling tool <NUM> is configured to place the slug <NUM> of carton blanks <NUM> against an endmost carton blank <NUM> in an advancing stack of cartons <NUM> in the magazine <NUM>.

As shown in <FIG>, the horizontal magazine <NUM> includes a throat <NUM> which extends between a receiving end <NUM> and a discharge end <NUM> of the magazine <NUM>. The magazine <NUM> includes a conveyor <NUM> to advance the stack of cartons <NUM> along the throat <NUM> and downstream to a cartoner (not shown) for further processing. In this regard, the throat <NUM> is configured to support the stack of cartons <NUM>, preferably in a controlled lean position, as shown, as the stack of cartons <NUM> is advanced from the receiving end <NUM> to the discharge end <NUM> of the magazine <NUM> by the conveyor <NUM>. The receiving end <NUM> is positioned near the case flipping station <NUM> and includes an envelope <NUM> in which the carton handling tool <NUM> is movable. As will be described in further detail below, the carton handling tool <NUM> is able to move in two axes of motion to receive each slug <NUM> of carton blanks <NUM> from the case flipper <NUM> and to position the slug <NUM> of carton blanks <NUM> in the carton blank magazine <NUM>.

For operational efficiency, it is important to maintain a minimal accumulation of carton blanks <NUM>, or "prime" of carton blanks <NUM>, in the magazine <NUM> to accommodate the downstream demand for carton blanks <NUM>. In this regard, the AML system <NUM> is configured as an on-demand type system to supply slugs of blank cartons <NUM> to the receiving end <NUM> of the magazine <NUM> as carton blanks <NUM> are removed from the magazine <NUM> at the discharge end <NUM>. Strategically located photo-eyes (not shown) provide the magazine control and ensure overall operational reliability. For example, the AML system <NUM> may include a low level photo-eye and a high level photo-eye. When the low level photo-eye is unblocked by the stack of cartons <NUM> in the magazine <NUM>, the AML system <NUM> will continue to position slugs of carton blanks <NUM> in the horizontal magazine <NUM> until the high level photo-eye is blocked at which point the AML system <NUM> magazine <NUM> loading cycle will stop. As long as the high level photo-eye is blocked, the horizontal magazine <NUM> cannot receive additional slugs of carton blanks <NUM>. Once the high level photo-eye is unblocked, there is enough space on the magazine <NUM> to receive additional slugs of carton blanks <NUM>.

To facilitate movement of the stack of cartons <NUM> along the horizontal magazine <NUM>, it is important to maintain a controlled lean of the stack of cartons <NUM>. Controlled lean ensures that the stack of cartons <NUM> can be fed down the throat <NUM> of the magazine <NUM> without jamming due to excessive gapping between cartons <NUM>, top and side carton shingling, or fall-back of the trailing-most carton group. Controlled lean also prevents marring and damage to cartons <NUM>. In this regard, it is desirable to condition the slug <NUM> of carton blanks <NUM> prior to positioning the slug <NUM> of carton blanks <NUM> in the magazine <NUM>. That way, when the slug <NUM> is positioned in the magazine <NUM>, the lean of the advancing stack of cartons <NUM> in the magazine <NUM> is maintained. However, inevitably a trailing or endmost carton <NUM> of the advancing stack of carton blanks <NUM> may fall down flat on the magazine <NUM> conveyor <NUM>. This phenomenon may be referred to as fall-back or a fallen carton blank, and it can include one or several fallen carton blanks <NUM>.

Typically, a fallen carton blank <NUM> requires manual intervention by an operator to fix. This requires the AML system <NUM> to be stopped so that an operator can manually upright the fallen carton blank <NUM>. This results in unnecessary downtime and added cost. As described in further detail below, embodiments of the carton handling system <NUM> are configured to both condition each slug <NUM> of carton blanks <NUM> prior to positioning the slug <NUM> of carton blanks <NUM> in the magazine <NUM> as well as upright fallen carton blanks <NUM> in the magazine <NUM> to eliminate the need for manual intervention and stoppage of the AML system <NUM>.

As shown in <FIG>, the AML system <NUM> is assembled around an operator platform <NUM>. The platform <NUM> allows an operator to interact with components of the AML system <NUM> to respond to auditory or visual alarms, manually load or prime the magazine <NUM>, tune components such as positioning of the case flipping station <NUM> and robotic device <NUM> relative to the carton handling system <NUM>, or otherwise operate the system <NUM>. The platform <NUM> may be where a Human Machine Interface (HMI) and one or more control cabinets <NUM> which house appropriate control equipment for components of the AML system <NUM> are located. To this end, components of the AML system <NUM>, including embodiments of the present invention, are responsive to stored programs for commanding operation of those components. The programs may be computer-readable program instructions for carrying out operations of the embodiments of the present invention. The computer-readable programs may be assembly language, source code, or object code written in any combination of one or more programming languages, and may be implemented using one or more computing devices or systems which may include a processor, a memory, an input/output (I/O) interface, and a Human Machine Interface (HMI), for example.

<FIG> illustrate details of the case flipping station <NUM> and the carton handling system <NUM>, and their interactions. As briefly described above, the robotic device <NUM> of the case flipping station <NUM> is configured to clamp, invert, and rotate each master case <NUM> to an accessible position over the carton handling system <NUM> to be retrieved by the carton handling tool <NUM>. In this regard, one master case <NUM> is moved via the conveyor <NUM> from the case receiving station <NUM> to a receiving zone <NUM> at the case flipping station <NUM>. Once the master case <NUM> is positioned within the receiving zone <NUM>, the robotic device <NUM> is programmed in a known manner to clasp the master case <NUM> by engaging the pair of kinematic arm clamps <NUM> with sides of the master case <NUM> to contain the master case <NUM> therebetween. The kinematic arm clamps each include a movable cover <NUM> configured to close over portions of the slug <NUM> of carton blanks <NUM> in the master case <NUM> to contain the slug <NUM> of carton blanks <NUM> therein during movement of the master case <NUM>. Thus, while the covers <NUM> are shown in an opened position, they are closed when the robotic device <NUM> is moving the master case <NUM>. The robotic device <NUM> pivots the contained master case <NUM> about a vertical axis B1 via a motor <NUM> to position the master case <NUM> over the carton handling tool <NUM>, as indicated by directional arrow A1. At the same time, the material handing device <NUM> rotates the master case <NUM> to invert the case <NUM> over the carton handling tool <NUM>, as indicated by directional arrows A2, via a second motor <NUM> which rotates the case <NUM> about a horizontal axis B2. When so positioned, as shown in <FIG>, a base <NUM> of the master case <NUM> is facing upward with the slug <NUM> of carton blanks <NUM> facing downward and accessible for retrieval by the carton handling tool <NUM>, as described in further detail below.

With reference to <FIG> and <FIG>, the carton handling tool <NUM> is movable to retrieve the slug <NUM> of carton blanks <NUM> from the inverted master case <NUM>. In this regard, the carton handling tool <NUM> includes a first compression jaw <NUM> and a second compression jaw <NUM> for clamping opposite ends of the slug <NUM> of carton blanks <NUM> within the master case <NUM>. The first compression jaw <NUM> and the second compression jaw <NUM> are spaced apart along a longitudinal length of an operative end <NUM> of the carton handling tool <NUM>. As will be described in further detail below, the length of the operative end <NUM> of the carton handling tool <NUM> is adjustable to both compress the slug <NUM> of carton blanks <NUM> with the first and second jaws <NUM>, <NUM>, and to accommodate for different sized slugs <NUM> of carton blanks <NUM>, for example. In any event, the first and second compression jaws <NUM>, <NUM> are operable to engage, compress, and hold the slug <NUM> of carton blanks <NUM> such that the plurality of blanks <NUM> are held against inclination prior to placement of the slug <NUM> at the endmost blank <NUM> in the advancing stack of blanks <NUM>.

As shown in <FIG>, the carton handling tool <NUM> moves in an upward direction along a first movement axes, as indicated by directional arrow A3, to retrieve the slug <NUM> of carton blanks <NUM> from the master case <NUM> being held in an inverted position by the material handling device <NUM>. In this regard, the carton handling tool <NUM> retrieves the slug <NUM> of carton blanks <NUM> from the material handling device <NUM> at a location above the plane of carton blanks <NUM> moving along the horizontal magazine <NUM>. Before clamping the slug <NUM> of carton blanks <NUM>, the carton handling tool <NUM> is configured to tamp the slug <NUM> of carton blanks <NUM> with the operative end <NUM> (<FIG>) to ensure that the upper edges and lower edges of each carton blank <NUM> are aligned. This tamping process is performed while the master case <NUM> is still held by the material handling device <NUM>, as shown in <FIG>. Once the slug <NUM> of carton blanks <NUM> has been tamped, the carton handling tool <NUM> compresses the slug <NUM> of carton blanks <NUM> between the first and second compression jaws <NUM>, <NUM> and removes the slug <NUM> of carton blanks <NUM> from the master case <NUM> by moving in a downward direction along the first movement axis A3. Simultaneously, the robotic device <NUM> may be configured to open the pair of kinematic arm clamps <NUM> on the master case <NUM> to facilitate removal of the slug <NUM> of carton blanks <NUM> therefrom. The carton handling tool <NUM> is movable in a second movement axis, as indicated by directional arrow A4, to place the slug <NUM> of carton blanks <NUM> in the carton blank magazine <NUM>. As described in further detail below, the carton handling tool <NUM> both conditions the slug <NUM> of carton blanks <NUM> and uprights a fallen carton blank <NUM> in the carton blank magazine <NUM>, if detected, with a carton lifting finger <NUM> prior to placing the slug <NUM> of carton blanks <NUM> in the carton blank magazine <NUM> behind the advancing stack of carton blanks <NUM>.

As briefly described above, the carton handling tool <NUM> is capable of horizontal movement (e.g., forward and backward movement along an X-axis) in the first axis of motion. The first axis of motion may be considered a first movement direction that includes both forward and backward movement of the carton handling tool <NUM> in the feed or machine direction. The first axis of motion, or movement direction, is indicated by directional arrow(s) A4 throughout this disclosure. Similarly, the carton handling tool <NUM> is capable of simultaneous vertical movement (e.g., upward and downward movement along a Y-axis) in the second axis of motion. The second axis of motion may be considered a second movement direction that includes both upward and downward movement of the carton handling tool <NUM> in a direction perpendicular to the feed or machine direction. The second axis of motion, or movement direction, is indicated by directional arrow(s) A3 throughout this disclosure.

Referring now to <FIG> and <FIG>, the carton handling system <NUM> is configured to move the carton handling tool <NUM> simultaneously in two axes of motion to retrieve the slug <NUM> of carton blanks <NUM> from the material handling robot <NUM> and to position the slug <NUM> of carton blanks <NUM> in the magazine <NUM> in the manner described above. In this regard, the carton handling system <NUM> includes a carriage assembly <NUM> having a carriage <NUM> configured to engage with and move along a horizontal linear guide rail <NUM> (<FIG>) for moving the carriage assembly <NUM> in the second movement direction A4. The carriage <NUM> supports a vertical linear guide rail <NUM> to which a support arm <NUM> for the carton handling tool <NUM> is operatively coupled. In this regard, the carton handling tool <NUM> is attached to one end of the support arm <NUM> with the opposite end of the support arm <NUM> being configured to be driven along a length of the vertical guide rail <NUM> in the first movement direction A3. Movement of the carriage <NUM> along the horizontal guide rail <NUM> moves the entire carriage assembly <NUM> in the second movement direction A4, however, movement of the support arm <NUM> along the vertical guide rail <NUM> only moves the carton handling tool <NUM> in the first movement direction A3. To this end, the carriage <NUM> may be driven along the horizontal guide <NUM> with a servo motor and belt configuration, a belt and sprocket configuration, or a lead screw, for example. Similarly, the support arm <NUM> may be driven along the vertical guide <NUM> with a servo motor and belt configuration, a belt and sprocket configuration, or a lead screw, for example.

The horizontal guide rail <NUM> is located below the plane of advancing carton blanks <NUM> moving along the horizontal magazine <NUM> and is configured to align the carriage <NUM> below the envelope <NUM> at the receiving end <NUM> of the magazine <NUM> to position the carton handling tool <NUM> within the envelope <NUM> (e.g., <FIG>). In this regard, movement of the carriage <NUM> along the horizontal guide rail <NUM> permits movement of the carton handling tool <NUM> within the envelope <NUM>. As described in further detail below, movement of the carton handling tool <NUM> along the second movement axis A4 and within the envelope <NUM> enables the carton handling tool <NUM> to "chase the tail" of the advancing stack of cartons <NUM> in the magazine <NUM> so as to place the slug <NUM> of carton blanks <NUM> at the endmost blank <NUM> in the advancing stack of cartons <NUM>. To this end, the second movement axis A4 of the carton handling tool <NUM> is generally codirectional with a movement axis of the advancing stack of cartons <NUM> in the magazine <NUM>.

With reference to <FIG>, the vertical guide rail <NUM> is also located below the magazine <NUM> and is in a parallel relationship with the support arm <NUM> of the carton handling tool <NUM> to thereby position the carton handling tool <NUM> within the envelope <NUM> at the receiving end <NUM> of the magazine <NUM>. In this regard, movement of the support arm <NUM> along the vertical guide rail <NUM> moves the carton handling tool <NUM> in to or out from the envelope <NUM> (e.g., extending from the envelop <NUM> or retracting into the envelope <NUM>). More particularly, movement of the carton handling tool <NUM> along the first movement axis A3 enables the carton handling tool <NUM> to extend upwardly to the material handling device <NUM> to receive the slug <NUM> of carton blanks <NUM>, as described above.

With continued reference to <FIG>, the carton handling system <NUM> includes a sensor arm <NUM> configured to locate a first sensor <NUM> and a second sensor <NUM> over the horizontal magazine <NUM>. More particularly, the sensor arm <NUM> is configured to locate the first and second sensors <NUM>, <NUM> over the throat <NUM> of the magazine <NUM> to place the throat <NUM> and the advancing stack of cartons <NUM> within a view area <NUM>, <NUM> of the first and second sensors <NUM>, <NUM>, respectively. The sensor arm <NUM> is coupled at one end to the carriage <NUM> of the carriage assembly <NUM> and extends to an opposite end where a bracket assembly <NUM> for supporting the first and second sensors <NUM>, <NUM> is located. As the sensor arm <NUM> is coupled to the carriage <NUM>, the sensor arm <NUM> is only moved in the second movement axis A4 with the carriage <NUM>. Thus, the sensor arm <NUM> does not move in the first movement axis A3 with the carton handling tool <NUM>. That way, the magazine <NUM> throat <NUM> and advancing stack of cartons <NUM> remains within the view areas <NUM>, <NUM> of the first and second sensors <NUM>, <NUM>. In one embodiment, the sensor arm <NUM> may be independently moveably in the second movement axis A4. In any event, the bracket assembly <NUM> may be angled to position the magazine <NUM> throat <NUM> and the advancing stack of cartons <NUM> within the view areas <NUM>, <NUM> of the first and second sensors <NUM>. The first sensor <NUM> is configured to detect a fallen carton blank <NUM> at the end of the advancing stack of cartons <NUM> and the second sensor <NUM> is configured to detect an endmost carton blank <NUM> in the advancing stack of cartons <NUM>.

With reference to <FIG> and <FIG>, details of the carton handling tool <NUM> are shown and will now be described. The carton handling tool <NUM> includes a housing <NUM> which extends between a front end <NUM> and a back end <NUM> of the carton handling tool <NUM>. The housing <NUM> is defined by a pair of side plates <NUM> which are coupled together in a spaced apart relationship to define an interior of the housing <NUM>. In this regard, the side plates <NUM> are coupled together via one or more cross-members <NUM> and suitable fasteners <NUM>, such as screws or bolts, for example. The cross-members <NUM> are configured to space the side plates <NUM> apart. As shown, one cross-member <NUM> is located at a base <NUM> of the housing <NUM> and is configured to attach the carton handling tool <NUM> to the support arm <NUM>. The carton handling tool <NUM> further includes a slide assembly <NUM> that is slideably coupled to the housing <NUM> to permit lateral movement of the slide assembly <NUM> relative to the housing <NUM>. The slide assembly <NUM> is located at the front end <NUM> of the carton handling tool <NUM> and includes a blank support plate <NUM> located at the operative end <NUM> of the carton handling tool <NUM>. More particularly, the blank support plate <NUM> extends between the front end <NUM> and the back end <NUM> of the housing <NUM>. The blank support plate <NUM> is configured to engage with the slug <NUM> of carton blanks <NUM> when received by the carton handling tool <NUM>, as described in further detail below.

The slide assembly <NUM> is slideably coupled to the housing <NUM> via a slide rail <NUM>. As shown, the slide rail <NUM> is coupled between the side plates <NUM> and disposed generally within the interior of the housing <NUM>. In this regard, the slide rail <NUM> supports the slide assembly <NUM> in a floating arrangement between the two sidewalls <NUM>. The slide assembly <NUM> is movable laterally (e.g., in a movement direction that is along the second movement axis A4 of the carton handling system <NUM>) relative to the housing <NUM> with a linear actuator <NUM>, as indicated by directional arrows A5. The linear actuator <NUM> may be a hydraulic, pneumatic, or electromechanical actuator. In any event, the blank support plate <NUM> includes a notch <NUM> to accommodate lateral movement of the slide assembly <NUM> by the actuator <NUM>. The notch <NUM> is configured to receive the cross-member <NUM> to which the second compression jaw <NUM> is operatively coupled therein as the slide assembly <NUM> is moved in a direction A5 toward the second compression jaw <NUM>. Movement of the slide assembly <NUM> in this direction A5 decreases the size, or length, of the operative end <NUM> and may be used to compress a slug <NUM> of carton blanks <NUM> between the first and second compression jaws <NUM>, <NUM>. To this end, the linear actuator <NUM> may be configured to measure a compression force and/or resistance of the slug <NUM> of carton blanks <NUM> to the compressive force applied by the actuator <NUM>.

As shown in <FIG>, the operative end <NUM> of the carton handling tool <NUM> includes the first compression jaw <NUM> and the second compression jaw <NUM> which are spaced apart from each other along a length of the operative end <NUM>. The first compression jaw <NUM> is located at the front end <NUM> of the carton handling tool <NUM> and pivotably mounted on the slide <NUM>. More particularly, the first compression jaw <NUM> is coupled to the blank support plate <NUM> with a pin <NUM> that defines a pivot axis of the first compression jaw <NUM>. The pivot axis is perpendicular to the movement axes A3, A4 of the carton handling tool <NUM>. The first compression jaw <NUM> is operatively connected to a linear actuator <NUM> via a series of linkages <NUM> so as to be pivotable about the pivot axis by the linear actuator <NUM>. As shown in <FIG>, the first compression jaw <NUM> is in an upright, unpivoted position. Pivotal movement of the first compression jaw <NUM> from the upright position is in a direction toward front end <NUM> of the carton handling tool <NUM>. The carton handling tool <NUM> may include at least one proximity sensor <NUM> to detect a pivotal position of the first compression jaw <NUM>.

The first compression jaw <NUM> further includes a protrusion <NUM> to which the blank lifting finger <NUM> is attached. The protrusion <NUM> extends from the first compression jaw <NUM> and front end <NUM> of the carton handling tool <NUM>. As shown, the lifting finger <NUM> and first compression jaw <NUM> are in an L-shaped configuration. In this regard, the finger <NUM> and first compression jaw <NUM> share the same pivot axis defined by the pin <NUM> such that as the first compression jaw <NUM> is pivoted about the pivot axis so too is the finger <NUM>. The finger <NUM> comprises a generally U-shaped bracket having a tip <NUM> configured to engage with a fallen carton blank <NUM> to lift the fallen carton blank <NUM> against a preceding carton blank at the end of the advancing stack of cartons <NUM>, as described in further detail below. In one embodiment, the finger <NUM> may be fixed to the slide assembly <NUM> so as to not pivot with first compression jaw <NUM>. Alternatively, the finger <NUM> may be fixed to the front end <NUM> of the carton handling device <NUM>, such as to the frame <NUM>, for example.

The second compression jaw <NUM> is located at the back end <NUM> of the carton handling tool <NUM> and is pivotably mounted to a cross-member <NUM> of the carton handling tool <NUM>. The second compression jaw <NUM> may have a gripping pad <NUM> to facilitate engagement between the compression jaw <NUM> and the slug <NUM> of carton blanks <NUM>, for example. As shown, the second compression jaw <NUM> is coupled to the cross-member <NUM> with a pin <NUM> that defines a pivot axis of the second compression jaw <NUM>. The second compression jaw <NUM> is operatively connected to a linear actuator <NUM> via a series of linkages <NUM> so as to be pivotable about the pivot axis, or pin <NUM>, by the linear actuator <NUM>. As shown in <FIG>, the second compression jaw <NUM> is in an upright, unpivoted position. Pivotal movement of the second compression jaw <NUM> from the upright position is in a direction toward front end <NUM> of the carton handling tool <NUM>. However, in an alternative embodiment, the second compression jaw <NUM> may be fixedly attached to the cross-member <NUM> so as to be fixed in the upright position.

With reference to <FIG>, operation of the carton handling tool <NUM>, and more particularly the first and second compression jaws <NUM>, <NUM>, to condition the slug <NUM> of carton blanks <NUM> retrieved by the carton handling tool <NUM>, will now be described in detail. As shown in <FIG>, the operative end <NUM> of the carton handling tool <NUM> is engaged with a slug <NUM> of carton blanks <NUM> to place the slug <NUM> of carton blanks <NUM> between the first compression jaw <NUM> and second compression jaw <NUM>, and the slug <NUM> of carton blanks <NUM> such that the slug <NUM> is in contact with the blank support plate <NUM>. This movement is configured to tamp the slug <NUM> of carton blanks <NUM> to ensure that the upper edges and lower edges of each carton blank <NUM> are aligned, as described above with respect to <FIG>. Once the slug <NUM> of carton blanks <NUM> has been tamped, or during the tamping process, the slide assembly <NUM> is moved in the direction of arrow A6 to compress the slug <NUM> of carton blanks <NUM> for handling and conditioning. <FIG> illustrates the slug <NUM> of carton blanks <NUM> in a compressed state with the first and second compression jaws <NUM>, <NUM> engaged with ends of the slug <NUM> of carton blanks <NUM>. When the slug <NUM> of carton blanks <NUM> is compressed, the carton handling tool <NUM> is able to remove the slug <NUM> of carton blanks <NUM> from the master case <NUM> and gently lower the slug <NUM> of carton blanks <NUM> down to the horizontal magazine <NUM>, as described in further detail below.

<FIG> illustrates the pivotal movement of the first and second compression jaws <NUM>, <NUM> to provide the slug <NUM> of carton blanks <NUM> with the desired parallelogram shape with the carton blanks <NUM> having a desired lean, or inclination. In this regard, the first and second compression jaws <NUM>, <NUM> are configured to simultaneously pivot, in a direction toward the front end <NUM> of the carton handling tool <NUM>, as indicated by directional arrows A7, to tilt the upper edges of each carton blank <NUM> in the slug <NUM> forward relative to their respective lower edges. Pivotal movement of the first and second jaws <NUM>, <NUM> is caused by movement of the linear actuators <NUM>, <NUM>, as indicated by directional arrows A8 and A9, respectively. To this end, the first and second jaws <NUM>, <NUM> may pivot with a range of between <NUM>° to <NUM>° from their upright, or vertical position. In the embodiment shown, the first and second jaws <NUM>, <NUM> are configured to pivot <NUM>° from upright, however, this may vary based on the type of carton blanks <NUM> being handled. <FIG> illustrates the slug <NUM> of carton blanks <NUM> held by the carton handling tool <NUM> and having a desired lean angle. To this end, <FIG> illustrates a conditioned slug <NUM> of carton blanks <NUM> that is ready to be positioned in the horizontal magazine <NUM>.

With reference to <FIG>, an automated method of retrieving a slug <NUM> of carton blanks <NUM>, conditioning the slug <NUM> of carton blanks <NUM>, and loading the slug <NUM> of carton blanks <NUM> in the connected horizontal magazine <NUM> using the carton handling tool <NUM> will now be described. This process may be referred to as a magazine loading cycle. In this regard, <FIG> illustrates the robotic device <NUM> holding an inverted master case <NUM> containing a slug <NUM> of carton blanks <NUM> over the carton handling system <NUM>. The robotic device <NUM> moves the master case <NUM> to the position shown in the manner described above with respect to <FIG>, for example. As shown in <FIG>, the carton handling tool <NUM> is in a home position within the envelope <NUM> of the horizontal magazine <NUM>. From the home position, the carton handling tool <NUM> is configured to move in an upward direction in the first movement axis A3 and toward the master case <NUM> to engage the slug <NUM> of carton blanks <NUM>. While moving toward the master case <NUM>, or before, the carton handling tool <NUM> is configured to laterally adjust the slide assembly <NUM> to accommodate for the size (e.g., a length) of the slug <NUM> of carton blanks <NUM>. Further, as shown schematically in <FIG>, the first compression jaw <NUM> may be in a pivoted position as the operative end <NUM> of the carton handling tool <NUM> is moved toward the slug <NUM> of carton blanks <NUM>.

Once the operative end <NUM>, and more particularly the blank support plate <NUM>, is engaged with the slug <NUM> of carton blanks <NUM>, and the slug <NUM> of carton blanks <NUM> has been tamped, the first compression jaw <NUM> is pivoted back to upright, as shown in <FIG>. With continued reference to <FIG>, the slide assembly <NUM> moves in the direction of arrow A10 to compress the slug <NUM> of carton blanks <NUM> between the first and second compression jaws <NUM>, <NUM> to then remove the slug <NUM> of carton blanks <NUM> from the master case <NUM>. The carton handling tool <NUM> moves downward in the first movement axis A3 to remove the slug <NUM> of carton blanks <NUM> from the master case <NUM>. The carton handling tool <NUM> continues to move downward to the home position to place the slug <NUM> of carton blanks <NUM> in line with the plane of carton movement along the horizontal magazine <NUM>, as shown in <FIG>. When so positioned, the slug <NUM> of carton blanks <NUM> has being held against inclination and generally has no lean. In this regard, the first and second compression jaws <NUM>, <NUM> hold the slug <NUM> of carton blanks <NUM> against inclination.

With continued reference to <FIG>, the carton handling tool <NUM> is moved in the second movement axis A4 to advance the slug <NUM> of carton blanks <NUM> toward the magazine <NUM>, and more particularly, toward the endmost blank <NUM> in the advancing stack of blanks <NUM> which is being advanced away from the carton handling tool <NUM> by the horizontal magazine <NUM>, as indicated by directional arrow A11. When the carton handling tool <NUM> meets, or catches up with the endmost blank <NUM> in the advancing stack of blanks <NUM>, which is detected by the second sensor <NUM>, the carton handling tool <NUM> operates the first and second compression jaws <NUM>, <NUM> to tilt the slug <NUM>, as shown in <FIG>. In this regard, the desired lean of the slug <NUM> is achieved via simultaneous pivoting motion of the first and second compression jaws <NUM>, <NUM> in the manner described above with respect to <FIG>. To this end, the stored energy released from the compressed slug <NUM> of carton blanks <NUM> along with the pivoting motion of the compression jaws <NUM>, <NUM> produces the desired tilt of the slug <NUM> of carton blanks <NUM>.

In one embodiment, during the operation illustrated in <FIG>, the carton handling tool <NUM> is configured to determine, using the second sensor <NUM>, the exact position of the endmost carton blank <NUM> and to then move to a predetermined distance away from the endmost carton blank <NUM> to take a first distance measurement to the endmost carton blank <NUM>. Assuming the first sensor <NUM> has not detected a fallen carton <NUM>, the carton handling tool <NUM> lowers down a small distance to take a second distance measurement to the endmost carton blank <NUM>. With the two distance measurements the angle of the endmost carton <NUM> is determined. Based on the calculated angle and the programmed set points, the carton handling tool <NUM> will adjust its positioning relative to the stack of cartons <NUM> (e.g., move toward the stack of cartons <NUM> on the magazine <NUM> or stop slight short) as well as adjust the angle of the slug <NUM> of carton blanks <NUM> being held by the carton handling tool <NUM> to match or otherwise accommodate for the measured lean of the advancing stack of cartons <NUM> in the magazine <NUM>.

With continued reference to <FIG>, once the slug <NUM> of carton blanks <NUM> has been conditioned to have a desired lean, or inclination, the carton handling tool <NUM> positions the slug <NUM> of carton blanks <NUM> at the endmost carton blank <NUM> in the advancing stack of blanks <NUM>, as shown. In this regard, the lean of the conditioned slug <NUM> of carton blanks <NUM> generally conforms to the lean of the advancing stack <NUM> of carton blanks in the horizontal magazine <NUM>. Once the conditioned slug <NUM> of carton blanks <NUM> has been positioned in the horizontal magazine <NUM>, the carton handling tool <NUM> retreats away from the slug <NUM> of carton blanks <NUM>, in a downward direction along the first movement axis A3 to release the slug <NUM> of carton blanks <NUM>. The carton handling tool <NUM> proceeds to return to the home position, as shown in <FIG>, to repeat the magazine <NUM> loading cycle described above with respect to <FIG> for a next slug <NUM> of carton blanks <NUM>. To this end, the on-demand configuration of the AML system <NUM> triggers the magazine <NUM> loading cycle.

With reference to <FIG>, an automated method of up-righting a fallen carton blank <NUM> with the carton handling tool <NUM> will now be described. This process may be referred to as a fallen carton blank correction cycle. The fallen carton blank correction cycle occurs after the carton handling tool <NUM> has retrieved the slug <NUM> of carton blanks <NUM> from the material handling device <NUM> (e.g., <FIG> described above) and before the slug <NUM> of carton blanks <NUM> is tilted to have a desired lean and placed on the horizontal magazine <NUM> (e.g., <FIG> described above). In this regard, <FIG> illustrates a same point in the magazine <NUM> loading cycle as illustrated in <FIG>. Thus, the fallen carton blank <NUM> correction cycle described below with respect to <FIG> is triggered if the carton handling tool <NUM> detects a fallen carton <NUM> as it is moved in the second movement axis A4 to advance the slug <NUM> of carton blanks <NUM> toward the magazine <NUM> which is being advanced away from the carton handling tool <NUM> by the horizontal magazine <NUM>, as indicated by directional arrow A11.

<FIG> illustrates the carton handling tool <NUM> moving toward the magazine <NUM> and the advancing stack of cartons <NUM>. As shown, there is a fallen carton blank <NUM> in the magazine <NUM>. The first sensor <NUM> is configured to detect the fallen carton blank <NUM> as the fallen carton blank <NUM> is moved into the view area <NUM> of the first sensor <NUM>, as shown in <FIG>. Once the fallen carton blank <NUM> has been detected, movement of the carton handling tool <NUM> is stopped. As shown in <FIG>, when the carton handling tool <NUM> is stopped, the finger <NUM> is positioned so as to extend generally along a side <NUM> (e.g., an underside) of the fallen carton <NUM> to position the tip <NUM> of the finger <NUM> adjacent to the side <NUM> of the fallen carton blank <NUM>. More particularly, the finger <NUM> is positioned along the side <NUM> between a midpoint and an upper edge <NUM> of the fallen carton blank <NUM>. When so positioned, the carton handling tool <NUM> is moved in an upward direction along the first movement axis A3 to lift the upper edge <NUM> of the fallen carton blank <NUM> away from the magazine <NUM>, as shown in <FIG>. As shown, the carton handling tool <NUM> is moved upwardly until the finger <NUM> nears the upper edge <NUM> of the fallen carton <NUM>. When so positioned, side edges <NUM> of the fallen carton <NUM> are angled relative to the movement plane of the magazine <NUM>. In this regard, the angle of the fallen carton <NUM> relative to the movement plane of the magazine <NUM> may be anywhere within a range of between <NUM>° to <NUM>°, for example.

Once the upper edge <NUM> of the fallen carton blank <NUM> has been lifted by the finger <NUM>, as shown in <FIG>, the carton handling tool <NUM> moves toward the advancing stack of cartons <NUM> in the second movement axis A4 to further lift and push the fallen carton blank <NUM> against a preceding blank <NUM> at the end of the advancing stack of blanks <NUM>. Movement of the carton handling tool <NUM> in this regard generally pivots the fallen carton blank <NUM> against the preceding blank <NUM> at the end of the advancing stack of blanks <NUM>, as shown by directional arrow A12 in <FIG> and <FIG>. Once the fallen carton blank <NUM> is positioned against the preceding blank <NUM> at the end of the advancing stack of blanks <NUM>, as shown in <FIG>, the carton handling tool <NUM> retreats via a combination of movements in the first movement axis A3 and the second movement axis A4 to place the slug <NUM> of carton blanks <NUM> in line with the plane of carton movement along the horizontal magazine <NUM> (e.g., <FIG>). The carton handling tool <NUM> then proceeds to condition and deliver the slug <NUM> of carton blanks <NUM> to the magazine <NUM>, as described above with respect to <FIG>.

With reference to <FIG>, wherein like reference numerals represent like features, details of an exemplary carton handling tool 30a are shown in accordance with another embodiment of the present invention. The primary differences between the carton handling tool 30a of this embodiment and the carton handling tool <NUM> of the previously described embodiment is that the carton handling tool 30a includes a fixed second compression jaw 60a. In this regard, conditioning of the slug <NUM> of carton blanks <NUM> to have a desired inclination, or lean, involves pivoting just the first compression jaw <NUM>. To this end, the stored energy released from the compressed slug <NUM> of carton blanks <NUM>, along with the pivotal movement of the first compression jaw <NUM>, produces the desired shape of the slug <NUM> of carton blanks <NUM>, as shown.

Claim 1:
A carton handling system (<NUM>) for loading a carton blank magazine (<NUM>) with a slug (<NUM>) of carton blanks (<NUM>), comprising:
a carriage assembly (<NUM>) having a carton handling tool (<NUM>), the carriage assembly (<NUM>) being capable of moving the carton handling tool (<NUM>) in two axes of motion to receive the slug (<NUM>) of carton blanks (<NUM>) and to position the slug (<NUM>) of carton blanks (<NUM>) in the carton blank magazine (<NUM>);
and characterized in that it comprises:
a finger (<NUM>) carried on the carton handling tool (<NUM>), wherein the carton handling tool (<NUM>) is movable to engage the finger (<NUM>) with an underside (<NUM>) of a fallen carton blank (<NUM>) lying at an end of an advancing stack of blanks (<NUM>) in the carton blank magazine (<NUM>) so as to lift the fallen carton blank (<NUM>) against a preceding blank (<NUM>) at the end of the advancing stack of blanks (<NUM>), and wherein the carton handling tool (<NUM>) is movable to position the slug (<NUM>) of carton blanks (<NUM>) at an endmost blank (<NUM>) in the advancing stack of blanks (<NUM>).