Patent Description:
Every day, companies around the world pack millions of items in cases (such as boxes formed from corrugated) to prepare them for shipping. Case sealers partially automate this process by applying pressure-sensitive tape to cases already packed with items and (in certain instances) protective dunnage to seal those cases shut. Random case sealers (a subset of case sealers) automatically adjust to the height of the case to-be-sealed so they can seal cases of different heights.

A typical random case sealer includes a top-head assembly with a pressure switch at its front end. The top-head assembly moves vertically under control of two pneumatic cylinders to accommodate cases of different heights. The top-head assembly includes a tape cartridge configured to apply tape to the top surface of the case as it moves past the tape cartridge. One known tape cartridge includes a front roller assembly, a cutter assembly, a rear roller assembly, a tape-mounting assembly, and a tension-roller assembly. A roll of tape is mounted to the tape-mounting assembly. A free end of the tape is routed through several rollers of the tension-roller assembly until the free end of the tape is adjacent a front roller of the front roller assembly with its adhesive side facing outward (toward the incoming cases).

In operation, an operator moves a case into contact with the pressure switch. In response, pressurized gas is introduced from a gas source into the two pneumatic cylinders to pressurize the volumes below their respective pistons to a first pressure to begin raising the top-head assembly. Once the top-head assembly ascends above the case so the case stops contacting the pressure switch, the operator moves the case beneath the top-head assembly, and the gas pressure in the pneumatic cylinders is reduced to a second, lower pressure. When pressurized at the second pressure, the pneumatic cylinders partially counter-balance the weight of the top-head assembly so the top-head assembly gently descends onto the top surface of the case.

A drive assembly of the case sealer moves the case relative to the tape cartridge. This movement causes the front roller of the front roller assembly to contact a leading surface of the case and apply the tape to the leading surface. Continued movement of the case relative to the tape cartridge forces the front roller assembly to retract against the force of a spring. This also causes the rear roller assembly to retract since the roller arm assemblies are linked. As the drive assembly continues to move the case relative to the tape cartridge, the spring forces the front roller to ride along the top surface of the case while applying the tape to the top surface. The spring also forces a rear roller of the rear roller assembly to ride along the top surface of the case (once the case reaches it).

As the drive assembly continues to move the case relative to the tape cartridge, the case contacts the cutter assembly and causes it to retract against the force of another spring, which leads to the cutter assembly riding along the top surface of the case. Once the drive assembly moves the case relative to the tape cartridge so the case's trailing surface passes the cutter assembly, the spring biases the cutter assembly back to its original position. Specifically, the spring biases an arm with a toothed blade downward to contact the tape and sever the tape from the roll, forming a free trailing end of the tape. At this point, the rear roller continues to ride along the top surface of the case, thereby maintaining the front and rear roller arm assemblies in their retracted positions.

Once the drive assembly moves the case relative to the tape cartridge so the case's trailing surface passes the rear roller, the spring forces the front and rear roller assemblies to return to their original positions. As the rear roller assembly does so, it contacts the trailing end of the severed tape and applies it to the trailing surface of the case to complete the sealing process. <CIT> relates to thrust members, for example idle rollers, supported by a taping head and disposed at two sides of a carton support base. The thrust members are approachable to each other beginning from a mutual maximum removal position to exert opposite pressures on the carton sides to limit the width of the upper longitudinal slot to be sealed. <CIT> relates to a case sealer that includes a top-head-actuating assembly configured to vary the speed of the top-head assembly when ascending and when descending onto the case. In certain embodiments the case sealer includes a tape cartridge configured to limit the forces imparted onto the leading and top surfaces of the case during sealing. <CIT> relates to a case sealer comprising a controller which makes use of timed control of signals provided by sensors located along the operation path as a means to prevent blockage of the sealer during a process to seal a case.

Occasionally, material may protrude from the top surface of the case (such as between the closed flaps of the top surface of the case) or otherwise be present on the top surface of the case as the operator moves the case beneath the top-head assembly. This material can interfere with the sealing process and, since this known case sealer cannot detect this undesired material, it could prevent the case sealer from completely sealing the case. This material could also damage the case sealer or the case itself.

Various embodiments of the present disclosure provide a random case sealer configured to interrupt the case-sealing process upon detecting an object between the top-head assembly and the top surface of the case.

One embodiment of the case sealer of the present disclosure comprises a base assembly, a top-head assembly supported by the base assembly, an actuator operably connected to the top-head assembly to move the top-head assembly relative to the base assembly, a first sensor configured to transmit an object-detected signal responsive to detecting an object and an object-undetected signal responsive to no longer detecting the object, a second sensor configured to transmit an object-detected signal responsive to detecting an object, and a controller communicatively connected to the first and second sensors and operably connected to the actuator. The controller is configured to: responsive to receiving a first object-detected signal from the first sensor, control the actuator to begin raising the top-head assembly; after receiving the first object-detected signal from the first sensor, responsive to receiving a first object-detected signal from the second sensor, begin monitoring for a second object-detected signal from the first sensor; and responsive to receiving the second object-detected signal from the first sensor, control the actuator to begin raising the top-head assembly.

While the systems, devices, and methods described herein may be embodied in various forms, the drawings show and the specification describes certain exemplary and non-limiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connection of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as coupled, mounted, connected, etc., are not intended to be limited to direct mounting methods, but should be interpreted broadly to include indirect and operably coupled, mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

Various embodiments of the present disclosure provide a random case sealer configured to interrupt the case-sealing process upon detecting an object between the top-head assembly and the top surface of the case. This prevents this object from damaging the case sealer or the case and prevents suboptimal sealing.

<FIG> shows one example embodiment of a case sealer <NUM> of the present disclosure. The case sealer <NUM> includes a base assembly <NUM>, a mast assembly <NUM>, a top-head assembly <NUM>, an upper tape cartridge <NUM>, and a lower tape cartridge (not shown for clarity). As shown in <FIG>, the case sealer <NUM> also includes several actuating assemblies and actuators configured to control movement of certain components of the case sealer <NUM>; multiple sensors S; and control circuitry and systems for controlling the actuating assemblies and the actuators (and other mechanical, electro-mechanical, and electrical components of the case sealer <NUM>) responsive to signals received from the sensors S.

The case sealer <NUM> includes a controller <NUM> communicatively connected to the sensors S to send and receive signals to and from the sensors S. The controller <NUM> is operably connected to the actuating assemblies and the actuators to control the actuating assemblies and the actuators. The controller <NUM> may be any suitable type of controller (such as a programmable logic controller) that includes any suitable processing device(s) (such as a microprocessor, a microcontroller-based platform, an integrated circuit, or an application-specific integrated circuit) and any suitable memory device(s) (such as random access memory, read-only memory, or flash memory). The memory device(s) stores instructions executable by the processing device(s) to control operation of the case sealer <NUM>.

The base assembly <NUM> is configured to align cases in preparation for sealing and to move the cases through the case sealer <NUM> while supporting the mast assembly <NUM> (which supports the top-head assembly <NUM>). As best shown in <FIG>, the base assembly <NUM> includes a base-assembly frame <NUM>, an infeed table <NUM>, an outfeed table <NUM>, a side-rail assembly <NUM> (not shown but numbered for clarity), a bottom-drive assembly <NUM>, and a barrier assembly <NUM>. The base assembly <NUM> defines an infeed end IN (<FIG>) of the case sealer <NUM> at which an operator (or an automated feed system) feeds cases to-be-sealed into the case sealer <NUM> (via the infeed table <NUM>) and an outfeed end OUT (<FIG>) of the case sealer <NUM> at which the case sealer <NUM> ejects sealed cases onto the outfeed table <NUM>.

The base-assembly frame <NUM> is formed from any suitable combination of solid and/or tubular members and/or plates fastened together. The base-assembly frame <NUM> is configured to support the other components of the base assembly <NUM>.

The infeed table <NUM> is mounted to the base-assembly frame <NUM> adjacent the infeed end IN of the case sealer <NUM>. The infeed table <NUM> includes multiple rollers on which the operator can place and fill a case and then use to convey the filled case to the top-head assembly <NUM>. The infeed table <NUM> includes an infeed-table sensor S1 (<FIG>), which may be any suitable sensor (such as a photoelectric sensor) configured to detect the presence of a case on the infeed table <NUM> (and, more particularly, the presence of a case at a particular location on the infeed table <NUM> that corresponds to the location of the infeed-table sensor S1). In other embodiments, another component of the case sealer <NUM> includes the infeed-table sensor S1. The infeed-table sensor S1 is communicatively connected to the controller <NUM> to send signals to the controller <NUM> responsive to detecting a case (an object-detected signal) and, afterwards, no longer detecting the case (an object-undetected signal), as described below.

The outfeed table <NUM> is mounted to the base-assembly frame <NUM> adjacent the outfeed end OUT of the case sealer <NUM>. The outfeed table <NUM> includes multiple rollers onto which the case is ejected after taping.

The side-rail assembly <NUM> is supported by the base-assembly frame <NUM> adjacent the infeed table <NUM> and includes first and second side rails 114a and 114b and a side-rail actuator <NUM> (<FIG>). The side rails 114a and 114b extend generally parallel to a direction of travel D (<FIG>) of a case through the case sealer <NUM> and are movable laterally inward (relative to the direction of travel D) to laterally center the case on the infeed table <NUM>. The side-rail actuator <NUM> is operably connected to the first and second side rails 114a and 114b (either directly or via suitable linkages) to move the side rails between: (<NUM>) a rest configuration (<FIG>) in which the side rails are positioned at or near the lateral extents of the infeed table <NUM> to enable an operator to position a case to-be-sealed between the side rails on the infeed table <NUM>; and (<NUM>) a centering configuration (<FIG>) in which the side rails (after being moved toward one another) contact the case and center the case on the infeed table <NUM>. The controller <NUM> is operably connected to the side-rail actuator <NUM> to control the side-rail actuator <NUM> to move the side rails 114a and 114b between the rest and centering configurations.

The side-rail actuator <NUM> may be any suitable type of actuator, such as a motor or a pneumatic cylinder fed with pressurized gas and controlled by one or more valves.

The bottom-drive assembly <NUM> is supported by the base-assembly frame <NUM> and (along with a top-drive assembly <NUM>, described below) configured to move cases in the direction D. The bottom-drive assembly <NUM> includes a bottom drive element and a bottom-drive-assembly actuator <NUM> (<FIG>) operably connected to the bottom drive element to drive the bottom drive element to (along with the top-drive assembly <NUM>) move cases through the case sealer <NUM>. In this example embodiment, the bottom-drive-assembly actuator <NUM> includes a motor that is operably connected to the bottom drive element-which includes an endless belt in this example embodiment-via one or more other components, such as sprockets, gearing, screws, tensioning elements, and/or a chain. The bottom-drive-assembly actuator <NUM> may include any other suitable actuator in other embodiments. The bottom-drive element may include any other suitable component or components, such as rollers, in other embodiments. The controller <NUM> is operably connected to the bottom-drive-assembly actuator <NUM> to control operation of the bottom-drive-assembly actuator <NUM>.

The bottom-drive assembly <NUM> supports a case-entry sensor S3 downstream of the infeed table <NUM> and the leading-surface sensor S2 (described below) and beneath the top-head assembly <NUM> so the case-entry sensor S3 can detect when a case enters the space below the top-head assembly <NUM>. As used herein, "downstream" means in the direction of travel D, and "upstream" means the direction opposite the direction of travel D. The case-entry sensor S3 includes a proximity sensor (or any other suitable sensor, such as a mechanical sensor) configured to detect the presence of a case. In other embodiments, the case-entry sensor S3 is supported by the mast assembly <NUM> or the top-head assembly <NUM>. The case-entry sensor S3 is communicatively connected to the controller <NUM> to send signals to the controller <NUM> responsive to detecting the case (an object-detected signal) and no longer detecting the case (an object-undetected signal).

The barrier assembly <NUM> includes four individually framed barriers (not labeled) that are formed from clear material, such as plastic or glass. The barriers are connected to the base-assembly frame <NUM> so one pair of barriers flanks the first top-head-mounting assembly <NUM> (described below) and the other pair of barriers flanks the second top-head-mounting assembly <NUM> (described below). When connected to the base-assembly frame <NUM>, the barriers are laterally offset from the top-head assembly <NUM> to prevent undesired objects from entering the area surrounding the top-head assembly <NUM> from the sides.

The mast assembly <NUM> is configured to support and control vertical movement of the top-head assembly <NUM> relative to the base assembly <NUM>. As best shown in <FIG> and <FIG>, the mast assembly <NUM> includes (in this example embodiment) identical first and second top-head-mounting assemblies <NUM> and <NUM> to which the top head <NUM> is attached and a top-head-actuating assembly <NUM> configured to control vertical movement of the top head <NUM>.

The first top-head-mounting assembly <NUM> is connected to one side of the base-assembly frame <NUM> via mounting plates and fasteners (not labeled) or in any other suitable manner. Similarly, the second top-head-mounting assembly <NUM> is connected to the opposite side of the base-assembly frame <NUM> via mounting plates and fasteners (not labeled) or in any other suitable manner. In this example embodiment, the first and second top-head-mounting assemblies <NUM> and <NUM> are fixedly connected to the base assembly <NUM>.

The first top-head-mounting assembly <NUM> includes an enclosure <NUM> that is connected to (via suitable fasteners or in any other suitable manner) and partially encloses part of the top-head-actuating assembly <NUM>. As best shown in <FIG>, <FIG>, the top-head-actuating assembly <NUM> includes first and second rail mounts 232a and 234a, first and second rails 232b and 234b, a first carriage <NUM>, and a first top-head-actuating-assembly actuator <NUM>. In this example embodiment, the first top-head-actuating-assembly actuator <NUM> includes a pneumatic cylinder fed with pressurized gas and controlled by one or more valves, though it may be any other suitable type of actuator (such as a motor) in other embodiments.

The first and second rail mounts 232a and 234a include elongated tubular members having a rectangular cross-section, and the first and second rails 232b and 234b are elongated solid (or in certain embodiments, tubular) members having a circular cross-section. The first rail 232b is mounted to the first rail mount 232a so the first rail 232b and the first rail mount 232a share the same longitudinal axis. The second rail 234b is mounted to the second rail mount 234a so the second rail 234b and the second rail mount 234a share the same longitudinal axis.

The first carriage <NUM> includes a body <NUM> that includes a first pair of outwardly extending spaced-apart mounting wings 242a and 242b, a second pair of outwardly extending spaced-apart mounting wings 242c and 242d, a pair of upwardly extending mounting ears 242e and 242f, four linear bearings 244a-244d, and a shaft <NUM>. Each mounting wing 242a-242f defines a mounting opening therethrough (not labeled). Each linear bearing 244a-244d defines a mounting bore therethrough (not labeled). The linear bearings 244a-244d are connected to the mounting wings 242a-242d, respectively, so the mounting openings of the mounting wings and the mounting bores of the linear bearings are aligned. The shaft <NUM> is received in the mounting openings of the mounting ears 242e and 242f so the shaft <NUM> extends between those mounting ears.

The first carriage <NUM> is slidably mounted to the first and second rails 232b and 234b via: (<NUM>) receiving the first rail 232b through the mounting openings in the mounting wings 242a and 242b and the mounting bores in the linear bearings 244a and 244b; and (<NUM>) receiving the second rail 234a through the mounting openings in the mounting wings 242c and 242d and the mounting bores in the linear bearings 244c and 244d. The first top-head-actuating-assembly actuator <NUM> is operably connected to the first carriage <NUM> to move the carriage along and relative to the rails 232b and 234b. Specifically, the first top-head-actuating-assembly actuator <NUM> is connected to a plate (not labeled) that extends between the first and second rail supports 232a and 234a and to the shaft <NUM>. This enables the first top-head-actuating-assembly actuator <NUM> to control movement of the first carriage <NUM> along the rails 232b and 234b.

The second top-head-mounting assembly <NUM> includes an enclosure <NUM> that is connected to (via suitable fasteners or in any other suitable manner) and partially encloses another part of the top-head-actuating assembly <NUM> (<FIG>). Although not separately shown for brevity (since these parts are identical to those described above that the first top-head-mounting assembly <NUM> encloses), these components of the top-head-actuating assembly <NUM> are numbered below for clarity and ease of reference. The top-head-actuating assembly <NUM> includes third and fourth rail mounts 272a and 274a, third and fourth rails 272b and 274b, a second carriage <NUM>, and a second top-head-actuating-assembly actuator <NUM> in the form of a second top-head-actuating-assembly actuator <NUM>. In this example embodiment, the second top-head-actuating-assembly actuator <NUM> includes a pneumatic cylinder fed with pressurized gas and controlled by one or more valves, though it may be any other suitable type of actuator (such as a motor) in other embodiments.

The third and fourth rail mounts 272a and 274a include elongated tubular members having a rectangular cross-section, and the third and fourth rails 272b and 274b are elongated solid (or in certain embodiments, tubular) members having a circular cross-section. The third rail 272b is mounted to the third rail mount 272a so the third rail 272b and the third rail mount 272a share the same longitudinal axis. The fourth rail 274b is mounted to the fourth rail mount 274a so the fourth rail 274b and the fourth rail mount 274a share the same longitudinal axis.

The second carriage <NUM> includes a body <NUM> that includes a first pair of outwardly extending mounting wings 282a and 282b, a second pair of outwardly extending mounting wings 282c and 282d, a pair of upwardly extending mounting ears 282e and 282f, four linear bearings 284a-284d, and a shaft <NUM>. Each mounting wing 282a-282f defines a mounting opening therethrough (not labeled). Each linear bearing 284a-284d defines a mounting bore therethrough (not labeled). The linear bearings 284a-284d are connected to the mounting wings 282a-282d, respectively, so the mounting openings of the mounting wings and the mounting bores of the linear bearings are aligned. The shaft <NUM> is received in the mounting openings of the mounting ears 282e and 282f so the shaft <NUM> extends between those mounting ears.

The second carriage <NUM> is slidably mounted to the third and fourth rails 272b and 274b via: (<NUM>) receiving the third rail 272b through the mounting openings in the mounting wings 282a and 282b and the mounting bores in the linear bearings 284a and 284b; and (<NUM>) receiving the fourth rail 274a through the mounting openings in the mounting wings 282c and 282d and the mounting bores in the linear bearings 284c and 284d. The second top-head-actuating-assembly actuator <NUM> is operably connected to the second carriage <NUM> to move the carriage along and relative to the rails 272b and 274b. Specifically, the second top-head-actuating-assembly actuator <NUM> is connected to a plate (not labeled) that extends between the third and fourth rail supports 272a and 274a and to the shaft <NUM>. This enables the second top-head-actuating-assembly actuator <NUM> to control movement of the second carriage <NUM> along the rails 272b and 274b.

The controller <NUM> is operably connected to the first and second top-head-actuating-assembly actuators <NUM> and <NUM> to control vertical movement of the top-head assembly <NUM>.

In other embodiments, the case sealer includes a single actuator configured to control the vertical movement of the top-head assembly.

The top-head assembly <NUM> is movably supported by the mast assembly <NUM> to adjust to cases of different heights and is configured to move the cases through the case sealer <NUM>, engage the top surfaces of the cases while doing so, and support the tape cartridge <NUM>. As best shown in <FIG> and <FIG>, the top-head assembly <NUM> includes a top-head-assembly frame <NUM>, a top-drive assembly <NUM>, a leading-surface sensor S2, a retraction sensor S4, and a case-exit sensor S5. In other embodiments, one or more other components of the case sealer <NUM> (such as the base assembly <NUM> and/or the mast assembly <NUM>) include the one or more of the sensors S2, S4, and S5.

The top-head-assembly frame <NUM> is configured to mount the top-head assembly <NUM> to the mast assembly <NUM> and to support the other components of the top-head assembly <NUM>, and is formed from any suitable combination of solid or tubular members and/or plates fastened together. The top-head-assembly frame <NUM> includes laterally extending first and second mounting arms <NUM> and <NUM> that are connected to the carriages <NUM> and <NUM>, respectively, of the first and second top-head-mounting assemblies <NUM> and <NUM> via suitable fasteners.

The top-drive assembly <NUM> is supported by the top-head-assembly frame <NUM> and (along with the bottom-drive assembly <NUM>, described above) configured to move cases in the direction D. The top-drive assembly <NUM> includes a top-drive element and a top-drive-assembly actuator <NUM> (<FIG>) operably connected to the top-drive element to drive the top-drive element to (along with the bottom-drive assembly <NUM>) move cases through the case sealer <NUM>. In this example embodiment, the top-drive-assembly actuator <NUM> includes a motor that is operably connected to the top-drive element-which includes an endless belt in this example embodiment-via one or more other components, such as sprockets, gearing, screws, tensioning elements, and/or a chain. The top-drive-assembly actuator <NUM> may include any other suitable actuator in other embodiments. The top-drive element may include any other suitable component or components, such as rollers, in other embodiments. The controller <NUM> is operably connected to the top-drive-assembly actuator <NUM> to control operation of the top-drive-assembly actuator <NUM>.

The leading-surface sensor S2 includes a mechanical paddle switch (or any other suitable sensor, such as a proximity sensor) positioned at a front end of the top-head-assembly frame <NUM> and configured to detect: (<NUM>) when the leading surface of a case initially contacts (or is within a predetermined distance of) the top-head assembly <NUM>; and (<NUM>) when an object is positioned between the top-head assembly <NUM> and the top surface of the case. The leading-surface sensor S2 is communicatively connected to the controller <NUM> to send signals to the controller <NUM> responsive to actuation (an object-detected signal) and de-actuation (an object-undetected signal) of the leading-surface sensor S2 (corresponding to the leading-surface sensor S2 detecting and no longer detecting the case and/or an object).

The retraction sensor S4 includes a proximity sensor (or any other suitable sensor) configured to detect the presence of a case. Here, although not shown, the retraction sensor S4 is positioned on the underside of the top-head-assembly frame <NUM> downstream of the case-entry sensor S3 so the retraction sensor S4 can detect when a case reaches a particular position underneath the top-head assembly <NUM> (here, a position just before the case contacts the front roller, as explained below). The retraction sensor S4 is communicatively connected to the controller <NUM> to send signals to the controller <NUM> responsive to detecting the case (an object-detected signal) and no longer detecting the case (an object-undetected signal).

The case-exit sensor S5 includes a proximity sensor (or any other suitable sensor) configured to detect the presence of a case. Here, although not shown, the case-exit sensor S5 is positioned on the underside of the top-head-assembly frame <NUM> near the rear end of the top-head-assembly frame <NUM> (downstream of the case-entry and retraction sensors S3 and S4) so the case-exit sensor S5 can detect when a case exits from beneath the top-head assembly <NUM>. The case-exit sensor S5 is communicatively connected to the controller <NUM> to send signals to the controller <NUM> responsive to detecting the case (an object-detected signal) and no longer detecting the case (an object-undetected signal).

The controller <NUM> is operably connected to: (<NUM>) the top-head-actuating assembly <NUM> and configured to control the top-head-actuating assembly <NUM> to control vertical movement of the top-head assembly <NUM> responsive to signals received from the sensors S2, S3, and S5; and (<NUM>) the upper tape cartridge <NUM> and the lower tape cartridge and configured to control the force-reduction functionality of these tape cartridges responsive to signals received from the sensor S4, as described in detail below in conjunction with <FIG>.

The upper tape cartridge <NUM> is removably mounted to the top head assembly <NUM> and configured to apply tape to a leading surface, a top surface, and a trailing surface of a case. Although not separately described, the lower tape cartridge is removably mounted to the base assembly <NUM> and configured to apply tape to the leading surface, the bottom surface, and the trailing surface of the case. As best shown in <FIG> and <FIG>, the tape cartridge <NUM> includes a first mounting plate M1 that supports a front roller assembly <NUM>, a rear roller assembly <NUM>, a cutter assembly <NUM>, a tape-mounting assembly <NUM>, a tension-roller assembly <NUM>, and a tape-cartridge-actuating assembly <NUM>. As best shown in <FIG>, a second mounting plate M2 is mounted to the first mounting plate M1 via multiple spacer shafts and fasteners (not labeled) to partially enclose certain elements of the front roller assembly <NUM>, the rear roller assembly <NUM>, the cutter assembly <NUM>, the tape-mounting assembly <NUM>, the tension-roller assembly <NUM>, and the tape-cartridge-actuating assembly <NUM> therebetween.

The front roller assembly <NUM> includes a front roller arm <NUM> and a front roller <NUM>. The front roller arm <NUM> is pivotably mounted to the first mounting plate M1 via a front roller-arm-pivot shaft PSFRONT so the front roller arm <NUM> can pivot relative to the mounting plate M1 about an axis AFRONT between a front roller arm extended position (<FIG>) and a front roller arm retracted position (<FIG>). The front roller arm <NUM> includes a front roller-mounting shaft 1120a, and the front roller <NUM> is rotatably mounted to the front roller-mounting shaft 1120a so the front roller <NUM> can rotate relative to the front roller-mounting shaft 1120a.

The rear roller assembly <NUM> includes a rear roller arm <NUM> and a rear roller <NUM>. The rear roller arm <NUM> is pivotably mounted to the first mounting plate M1 via a rear roller-arm-pivot shaft PSREAR so the rear roller arm <NUM> can pivot relative to the mounting plate M1 about an axis AREAR between a rear roller arm extended position (<FIG>) and a rear roller arm retracted position (<FIG>). The rear roller arm <NUM> includes a rear roller-mounting shaft 1220a, and the rear roller <NUM> is rotatably mounted to the rear roller-mounting shaft 1220a so the rear roller <NUM> can rotate relative to the rear roller-mounting shaft 1220a.

A rigid first linking member <NUM> is attached to and extends between the first roller arm <NUM> and the second roller arm <NUM>. The first linking member <NUM> links the front and rear roller assemblies <NUM> and <NUM> so: (<NUM>) moving the front roller arm <NUM> from the front roller arm extended position to the front roller arm retracted position causes the first linking member <NUM> to force the rear roller arm <NUM> to move from the rear roller arm extended position to the rear roller arm retracted position (and vice-versa); and (<NUM>) moving the rear roller arm <NUM> from the rear roller arm extended position to the rear roller arm retracted position causes the first linking member <NUM> to force the front roller arm <NUM> to move from the front roller arm extended position to the front roller arm retracted position (and vice-versa).

The tape-cartridge-actuating assembly <NUM> (<FIG>) includes a roller-arm-actuating assembly <NUM> and a cutter-arm-actuating assembly <NUM>.

The roller-arm-actuating assembly <NUM> is configured to move the linked front and rear roller arms <NUM> and <NUM> between their respective extended and retracted positions. As best shown in <FIG>, in this example embodiment the roller-arm-actuating assembly <NUM> includes a support plate <NUM> and a roller-arm actuator <NUM> pivotably attached to the support plate <NUM> via a pin assembly <NUM>. The roller-arm actuator <NUM> may be any suitable actuator, such as a motor or a pneumatic cylinder fed with pressurized gas and controlled by one or more valves.

The roller-arm actuator <NUM> is operably connected to the front roller assembly <NUM> to control movement of the front roller arm <NUM> and the rear roller arm <NUM> linked to the front roller arm <NUM> between their respective extended and retracted positions. More specifically, the roller-arm actuator <NUM> is coupled between the mounting plate M2 and the first roller arm assembly <NUM> via attachment of the support plate <NUM> to the mounting plate M2 and attachment of the roller-arm actuator <NUM> to the shaft <NUM> of the front roller assembly <NUM>.

The controller <NUM> is operably connected to the roller-arm actuator <NUM> and configured to control the roller-arm actuator <NUM> and therefore the positions of the front and rear roller arms <NUM> and <NUM>.

As best shown in <FIG> and <FIG>, the cutter assembly <NUM> includes a cutter arm <NUM>, a cutting-device cover pivot shaft <NUM>, a cutter-arm-actuator-coupling element <NUM>, a cutting-device-mounting assembly <NUM>, a cutting device <NUM> including a toothed blade (not labeled) configured to sever tape, a cutting-device cover <NUM>, a cutting-device pad <NUM>, and a rotation-control plate <NUM>.

The cutter arm <NUM> includes a cylindrical surface 1301a that defines a cutter arm mounting opening. The cutter arm <NUM> is pivotably mounted (via the cutter arm mounting opening) to the first mounting plate M1 via the front roller-arm-pivot shaft PSFRONT and bushings 1303a and 1303b so the cutter arm <NUM> can pivot relative to the mounting plate M1 about the axis AFRONT between a cutter arm extended position (<FIG>) and a cutter arm retracted position (<FIG>).

The cutter-arm-actuator-coupling element <NUM> includes a support plate <NUM> and a coupling shaft <NUM> extending transversely from the support plate <NUM>. The support plate <NUM> is fixedly attached to the cutter arm <NUM> via fasteners <NUM> so the coupling shaft <NUM> is generally parallel to and coplanar with the axis AFRONT.

The cutting-device-mounting assembly <NUM> is fixedly mounted to the support arm <NUM> (such as via welding) and is configured to removably receive the cutting device <NUM>. That is, the cutting-device-mounting assembly <NUM> is configured so the cutting device can be removably mounted to the cutting-device-mounting assembly <NUM>. The cutting-device-mounting assembly <NUM> is described in <CIT> (the entire contents of which are incorporated herein by reference), though any other suitable cutting-device-mounting assembly may be used to support the cutting device <NUM>.

The cutting-device cover <NUM> includes a body <NUM> and a finger <NUM> extending from the body <NUM>. A pad <NUM> is attached to the body <NUM>. The cutting-device cover <NUM> is pivotably mounted to the support arm <NUM> via mounting openings (not labeled) and the cutting-device cover pivot shaft <NUM>. Once attached, the cutting-device cover <NUM> is pivotable about the axis ACOVER relative to the cutter arm <NUM> and the cutting device mount <NUM> from front to back and back to front between a closed position and an open position. A cutting-device cover biasing element <NUM>, which includes a torsion spring in this example embodiment, biases the cutting-device cover <NUM> to the closed position. When in the closed position, the cutting-device cover <NUM> generally encloses the cutting device <NUM> so the pad <NUM> contacts the toothed blade of the cutting device <NUM>. When in the open position, the cutting-device cover <NUM> exposes the cutting device <NUM> and its toothed blade.

The cutting-device cover pivot shaft <NUM> is also attached to the rotation-control plate <NUM>. The rotation-control plate <NUM> includes a slot-defining surface <NUM> that defines a slot. The surface <NUM> acts as a guide (not shown) for a bushing that is attached to the mounting plate M2. The bushing provides lateral support for the cutter assembly <NUM> to generally prevent the cutter assembly from moving toward or away from the mounting plates M1 and M2 and interfering with other components of the tape cartridge <NUM> when in use.

The cutter-arm-actuating assembly <NUM> is configured to move the cutter arm <NUM> between its retracted position and its extended position. As best shown in <FIG>, in this example embodiment the cutter-arm-actuating assembly <NUM> includes a cutter-arm actuator <NUM>. The cutter-arm actuator <NUM> may be any suitable actuator, such as a motor or a pneumatic cylinder fed with pressurized gas and controlled by one or more valves.

The cutter-arm actuator <NUM> is operably connected to the cutter assembly <NUM> to control movement of the cutter arm <NUM> from its retracted position to its extended position. More specifically, the cutter-arm actuator <NUM> is coupled between the mounting plate M1 and the cutter assembly <NUM> via attachment to the shaft <NUM> and to the coupling shaft <NUM> of the cutter-arm-actuator-coupling element <NUM>.

The controller <NUM> is operably connected to the cutter-arm actuator <NUM> and configured to control the cutter-arm actuator <NUM> and therefore the positions of the cutter arm <NUM> and <NUM>.

The tape-mounting assembly <NUM> includes a tape-mounting plate <NUM> and a tape-core-mounting assembly <NUM> rotatably mounted to the tape-mounting plate <NUM>. The tape-core-mounting assembly <NUM> is further described in <CIT>, (though other tape core mounting assemblies may be used in other embodiments). A roll R of tape is mountable to the tape-core-mounting assembly <NUM>.

The tension-roller assembly <NUM> includes several rollers (not labeled) rotatably disposed on shafts that are supported by the first mounting plate M1. A free end of the roll R of tape mounted to the tape-core-mounting assembly <NUM> is threadable through the rollers until the free end is adjacent the front roller <NUM> of the front-roller assembly <NUM> with its adhesive side facing outward in preparation for adhesion to a case. The tension-roller assembly <NUM> is further described in <CIT>, (though other tension roller assemblies may be used in other embodiments).

Operation of the case sealer <NUM> to seal a case C is now described with reference to the flowchart shown in <FIG>, which shows a case-sealing process <NUM>, and <FIG>, which show the case sealer <NUM> during selected stages of the case-sealing process <NUM>.

Initially, the top-head assembly <NUM> is at its initial (lower) position, and the side rails 114a and 114b are in their rest configuration. The controller <NUM> controls the bottom-drive-assembly actuator <NUM> and the top-drive-assembly actuator <NUM> to drive the bottom drive element of the base assembly <NUM> and the top-drive element of the top-head assembly, respectively, as block <NUM> indicates.

The operator positions the case C onto the infeed table <NUM>. The infeed-table sensor S1 detects the presence of the case C, as block <NUM> indicates, and in response sends a corresponding object-detected signal to the controller <NUM>. Responsive to receiving that object-detected signal, the controller <NUM> controls the side-rail actuator <NUM> to move the side rails 114a and 114b from the rest configuration to the centering configuration so the side rails 114a and 114b move laterally inward to engage and center the case C on the infeed table <NUM>, as block <NUM> indicates and as shown in <FIG>.

The operator then moves the case C into contact with the leading-surface sensor S2. This causes the leading-surface sensor S2 (via the case C contacting and actuating the paddle switch of the leading-surface sensor S2) to detect the case C, as block <NUM> indicates, and in response send a corresponding object-detected signal to the controller <NUM>. Responsive to receiving the object-detected signal, the controller <NUM> controls the top-head-actuating assembly <NUM> (and, more particularly, the first and second top-head-actuating-assembly actuators <NUM> and <NUM>) to begin raising the top-head assembly <NUM>, as block <NUM> indicates and as shown in <FIG>.

As the top-head assembly <NUM> moves upward, the leading-surface sensor S2 eventually stops detecting the case C, as block <NUM> indicates and as shown in <FIG> and <FIG>. This indicates that the top-head assembly <NUM> has ascended above the top surface of the case C. In response to no longer detecting the case C, the leading-surface sensor S2 sends a corresponding object-undetected signal to the controller <NUM>. Responsive to receiving that signal, the controller <NUM> controls the top-head-actuating assembly <NUM> (and more particularly the first and second top-head-actuating-assembly actuators <NUM> and <NUM>) to enable the top-head assembly <NUM> to stop its ascent and begin descending under its own weight, as block <NUM> indicates.

Once the top-head assembly <NUM> ascends above the top surface of the case C, the operator moves the case C beneath the top-head assembly <NUM> and into contact with the bottom-drive assembly <NUM>, as shown in <FIG>. The case-entry sensor S3 detects the presence of the case C beneath the top-head assembly <NUM> and in response sends a corresponding object-detected signal to the controller <NUM>, as block <NUM> indicates.

Responsive to receiving that object-detected signal, the controller <NUM> begins monitoring for: (<NUM>) another object-detected signal from the leading-surface sensor S2 that, if received, indicates the leading-surface sensor S2 has detected an object between the top-head assembly <NUM> and the top surface of the case C, as diamond <NUM> indicates; and (<NUM>) an object-detected signal from the retraction sensor S4 that, if received, indicates the retraction sensor S4 detects the case C, as diamond <NUM> indicates. In the meantime, the top- and bottom-drive assemblies <NUM> and <NUM> begin moving the case C in the direction D.

Responsive to receiving another object-detected signal from the leading-surface sensor S2 (indicating that the leading-surface sensor S2 has detected an object between the top-head assembly <NUM> and the top surface of the case C via the object actuating the paddle switch of the leading-surface sensor S2), the controller <NUM> controls the top-head actuating assembly <NUM> (and, more particularly, the first and second top-head-actuating-assembly actuators <NUM> and <NUM>) to move the top-head assembly <NUM> to a raised position, which in this example embodiment is the position furthest from its initial position and the base assembly <NUM>, and controls the bottom-drive-assembly actuator <NUM> and the top-drive-assembly actuator <NUM> to stop driving the bottom drive element of the base assembly <NUM> and the top-drive element of the top-head assembly <NUM>, as block <NUM> indicates. This terminates the case-sealing process <NUM> and gives the operator the chance to remove the object from the top surface of the case C before resetting the case sealer <NUM> and carrying out the case-sealing process <NUM> again.

If before receiving another object-detected signal from the leading-surface sensor S2 the controller <NUM> receives an object-detected signal from the retraction sensor S4 (indicating that the retraction sensor S4 detected the case C), the controller <NUM> stops monitoring for another object-detected signal from the leading-surface sensor S2 and controls the roller-arm actuator <NUM> and the cutter-arm actuator <NUM> to move the first and second roller arms <NUM> and <NUM> and the cutter arm <NUM> to their respective retracted positions, as block <NUM> indicates. The leading surface of the case C contacts the front roller <NUM> of the tape cartridge <NUM> as the front roller arm <NUM> is moving to its retracted position, which causes the tape positioned on the front roller <NUM> to adhere to the leading surface of the case C. When the front and rear roller arms <NUM> and <NUM> are in their retracted positions, the front and rear rollers <NUM> and <NUM> are positioned so they apply enough pressure to the tape to adhere the tape to the top surface of the case C. When the cutter arm <NUM> is in its retracted position, the cutter arm <NUM> does not contact the top surface of the case C (though in certain embodiments it may do so). The controller <NUM> controls the roller-arm actuator <NUM> and the cutter-arm actuator <NUM> to retain the front and rear roller arms <NUM> and <NUM> and the cutter arm <NUM> in their respective retracted positions as the top- and bottom-drive assemblies <NUM> and <NUM> move the case C past the tape cartridge <NUM>.

The case C eventually moves off of the infeed table <NUM>, at which point the infeed-table sensor S1 stops detecting the case C and sends a corresponding object-undetected signal to the controller <NUM>. Responsive to receiving that object-undetected signal, the controller <NUM> controls the side-rail actuator <NUM> to move the side rails 114a and 114b from the centering configuration to the rest configuration to make space on the infeed table <NUM> for the next case to-be-sealed.

At some point, the case-exit sensor S5 detects the presence of the case C, as block <NUM> indicates (though this may occur after the retraction sensor S4 stops detecting the case C depending on the length of the case), and sends a corresponding object-detected signal to the controller <NUM>.

Once the retraction sensor S4 stops detecting the case (indicating that the case has moved past the retraction sensor S4), the retraction sensor S4 sends a corresponding object-undetected signal to the controller <NUM>, as block <NUM> indicates. In response, the controller <NUM> controls the roller-arm actuator <NUM> to return the first and second roller arms <NUM> and <NUM> to their respective extended positions to apply tape to the trailing surface of the case and controls the cutter-arm actuator <NUM> to return the cutter arm <NUM> to its extended position to cut the tape from the roll, as blocks <NUM> and <NUM> indicate. As this occurs, the finger <NUM> of the cutting-device cover <NUM> contacts the top surface of the case so the cutting-device cover <NUM> pivots to the open position and exposes the cutting device <NUM>. Continued movement of the cutter arm <NUM> brings the toothed blade of the cutting device <NUM> into contact with the tape and severs the tape from the roll R. As the front and rear roller arms <NUM> and <NUM> move back to their extended positions, the rear roller arm <NUM> moves so the rear roller <NUM> contacts the severed end of the tape and applies the tape to the trailing surface of the case C to complete the taping process.

The top- and bottom-drive assemblies <NUM> and <NUM> continue to move the case C until it exits from beneath the top-head assembly <NUM> onto the outfeed table <NUM>, at which point the case-exit sensor S5 stops detecting the case, as block <NUM> indicates, and sends a corresponding object-undetected signal to the controller <NUM>. The top-head assembly <NUM> then descends back to its initial position under its own weight, as shown in <FIG>.

In some embodiments, the tape cartridge includes biasing elements that bias the roller arms and the cutter arm to their respective extended positions. The biasing elements eliminate the need for direct actuation of the roller arms and the cutter arm from their respective retracted positions to their respective extended positions.

In certain embodiments, the controller is separate from and in addition to the sensors. In other embodiments, the sensors act as their own controllers. For instance, in one embodiment, the retraction sensor is configured to directly control the cutter and roller arm actuators responsive to detecting the presence of and the absence of the case, the infeed-table sensor is configured to directly control the side rail actuator responsive to detecting the presence of and the absence of the case, and the leading-surface and top-surface sensors are configured to directly control the top head actuator responsive to detecting the presence of and the absence of the case (or contact with the case).

Claim 1:
A case sealer (<NUM>) comprising:
a base assembly (<NUM>);
a top-head assembly (<NUM>) supported by the base assembly (<NUM>);
an actuator (<NUM>, <NUM>) operably connected to the top-head assembly (<NUM>) configured to move the top-head assembly (<NUM>) relative to the base assembly (<NUM>);
a first sensor (S2) configured to transmit an object-detected signal responsive to detecting an object and an object-undetected signal responsive to no longer detecting the object;
a second sensor (S3) configured to transmit an object-detected signal responsive to detecting an object; and
a controller (<NUM>) communicatively connected to the first and second sensors (S2, S3) and operably connected to the actuator, the controller (<NUM>) configured to, during a process to seal a case:
responsive to receiving a first object-detected signal from the first sensor (S2), control the actuator to begin raising the top-head assembly (<NUM>); the controller (<NUM>) being characterized in that:
after receiving the first object-detected signal from the first sensor (S2), responsive to receiving a first object-detected signal from the second sensor (S3), the controller (<NUM>) is configured to begin monitoring for a second object-detected signal from the first sensor (S2); and
responsive to receiving the second object-detected signal from the first sensor (S2), the controller (<NUM>) is configured to control the actuator to begin raising the top-head assembly (<NUM>).