Improvements relating to packaging

Abstract

An end effector adapted to be carried by a robotic positioning apparatus for packaging product items, the end effector being adapted in use to hold a top open elongate container (tube) in an inverted orientation, wherein the tube has a closed bottom end and an open top end; the end effector comprising: at least one actuatable moving element located on the end effector so as to be adjacent the open end of a tube held by the end effector; wherein the actuatable moving element is configured to be operable between: an extended position which extends at least partially over the open end of a tube held by the end effector to at least partially obstruct the open end of the tube; and a retracted position such that the open end of the container is substantially unobstructed to allow product items to be received in the tube.

Description

[0001] CLAIM OF PRIORITY

[0002] This application is based on provisional specification filed in relation to New Zealand patent application number 763219, the entire contents of which are incorporated herein by reference. TECHNICAL FIELD

[0003] The present invention relates to an apparatus for packing objects in tubes and in particular for packing fruit or other perishable items / foodstuffs in tubes. BACKGROUND

[0004] Apples and other fruit items are traditionally packed in boxes. To minimise damage to the fruit, the fruit is often supported in trays within the box to keep the fruit separate from adjacent fruit. Individual boxes can include one or more layers of fruit, each layer being supported by a tray.

[0005] The applicant introduces a new method of packing fruit (apples) by packing the apples in tubes rather than in trays in boxes. Each tube typically contains two or more fruit items, for example five apples.

[0006] The tubes can be cylindrical or can have a cross-sectional shape such as square, triangular or other shape. The internal dimensions of the tube are commensurate with the external dimensions of the fruit such that, when full, the tube accommodates a single row or column of fruit. For example, in a cylindrical tube, the internal diameter of the tube is preferably slightly larger than the maximum expected diameter of the fruit. The expected maximum diameter of the fruit can be based on known fruit size distribution for the particular variety and / or type of fruit.

[0007] Packing fruit in tubes can result in a less efficient packing process. Each fruit item cannot be dropped into the tube as physical collisions between the fruit as each fruit item is dropped into the tube can cause damage (scratches) to the fruit during packing. Moreover, unlike packing fruit in boxes, each fruit item must be added to the tube one at a time. This packing process can be time consuming and therefore can increase the cost of the packing process.

[0008] It is an object of the present invention to address one or more of the above mentioned problems or at least to provide the public with a useful choice.

[0009] All references, including any patents or patent applications cited in this specification, are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of the references states what their authors assert, and applicants reserve the right to challenge the accuracy and pertinency of the cited documents. It will be clearly understood that, although a number of prior art publications are referred to herein, this reference does not constitute an admission that any of these documents forms part of the common general knowledge in the art, in New Zealand or in any other country. SUMMARY

[0010] According to an aspect of the present application there is provided an end effector adapted to be carried by a robotic positioning apparatus for packaging product items, the end effector being adapted in use to hold a top open elongate container (tube) in an inverted orientation, wherein the tube has a closed bottom end and an open top end; the end effector comprising:

[0011] at least one actuatable moving element located on the end effector so as to be adjacent the open end of a tube held by the end effector;

[0012] wherein the actuatable moving element is configured to be operable between:

[0013] an extended position in which the actuatable moving element extends at least partially over the open end of a tube held by the end effector to at least partially obstruct the open end of the tube; and

[0014] a retracted position such that the open end of the container is substantially unobstructed to allow product items to be received in the tube.

[0015] According to a second aspect of the present application there is provided an end effector wherein the end effector comprises a frame for receiving the tube.

[0016] According to a third aspect of the present application there is provided an end effector wherein the actuatable moving element is located adjacent one end of the frame.

[0017] According to a fourth aspect of the present application there is provided an end effector wherein the actuatable moving element is made of a soft, resilient material and is elastically deformable between a first shape when in the extended position and a second shape when in the retracted position.

[0018] According to a fifth aspect of the present application there is provided an end effector wherein the first shape is circular.

[0019] According to a sixth aspect of the present application there is provided an end effector substantially as hereinbefore described wherein the second shape is non-circular or approximately elliptical.

[0020] According to a seventh aspect of the present application there is provided an end effector substantially as hereinbefore described wherein the actuatable moving element is substantially annular or has a substantially annular central portion.

[0021] According to an eighth aspect of the application, there is provided an end effector, wherein the actuatable movement element comprises a first portion and a second portion, each comprising an arcuate portion and a transverse member extending from each end of the arcuate portion, the first portion and the second portion being diametrically opposed, wherein the transverse member of the first portion is in contact with or adjacent to the transverse member of the second portion.

[0022] According to a ninth aspect of the application, there is provided an end effector, wherein, in the retracted position, a gap is provided between the proximal or radially inward portions of the transverse members of the first and second portions, and in the extended position, the arcuate portions are elastically deformed and the proximal ends of the transverse members of the first and second portions move together to close the gap.

[0023] According to a tenth aspect of the application, there is provided an end effector, wherein the end effector comprises:

[0024] a holding device configured to:

[0025] clamp the tube and secure the tube to the end effector; and

[0026] wherein the holding device clamps the tube adjacent to the closed bottom end of the tube.

[0027] Preferably, the holding device deforms the cross-sectional shape of the tube so as to assist frictional fixation of the position of the product item within the tube during a packaging operation.

[0028] According to an eleventh aspect of the application, there is provided an end effector, wherein the holding device comprises at least one movable component movable between a disengaged position, in which the movable component is not in contact with the tube, and an engaged position, in which the movable component is in contact with the tube to compress the tube and deform the tube.

[0029] According to a twelfth aspect of the application, there is provided an end effector, wherein the robotic positioning apparatus provides at least four degrees of freedom to move the end effector along x, y and z axes relative to a product item to be packaged and to rotate the end effector about a horizontal axis between an inverted orientation and an upright orientation.

[0030] According to a thirteenth aspect of the application, there is provided a product packaging apparatus, wherein the apparatus comprises a controller programmed to:

[0031] i) controlling the positioning apparatus to position the end effector vertically above a first product item to be packaged in an inverted orientation in the x and y directions; and to move the end effector vertically downwards to receive the first product item in the tube within the end effector; and

[0032] ii) if required, actuating the actuably movable element from the retracted position to the extended position to hold a first fruit item in the tube, and then once within the tube, actuating the actuably movable element to the retracted position to hold the first fruit item within the tube; and

[0033] iii) controlling the positioning apparatus to move the end effector vertically upwards.

[0034] Preferably, the positioning apparatus can be in the form of a robot.

[0035] However, it is envisaged that other positioning apparatuses capable of moving an end effector in three-dimensional space can be employed in the present application.

[0036] According to a fourteenth aspect of the present application, there is provided a product packaging apparatus substantially as hereinbefore described, wherein the controller is further programmed to:

[0037] iv) controlling the positioning apparatus to move the end effector in the x and y directions to position the end effector vertically above a further fruit item, and to move the end effector vertically downwards to position a next fruit item adjacent to or in contact with the further fruit item;

[0038] v) actuating the actuably movable element from the retracted position to the extended position;

[0039] vi) controlling the positioning apparatus to continue to move the end effector vertically downwards to receive a further product item in the tube within the end effector;

[0040] vii) actuating the actuably movable element from the retracted position to the extended position to hold the first fruit item and the further fruit item in the tube; and

[0041] viii) controlling the positioning apparatus to move the end effector vertically upwards; and

[0042] ix) repeating steps iv) to viii) until the tube is full.

[0043] According to a fifteenth aspect of the present application, there is provided a product packaging apparatus substantially as hereinbefore described, wherein the controller is further programmed to:

[0044] x) when the tube is full, controlling the robotic positioning apparatus to rotate the end effector from the inverted orientation to an upright orientation to position the open end of the tube uppermost and to move the end effector to a release area to release the tube from the end effector.

[0045] According to a sixteenth aspect of the application, there is provided a product packaging apparatus substantially as hereinbefore described, wherein the controller is further programmed to control the robotic positioning apparatus to move the end effector vertically upwards to release the tube from the end effector.

[0046] According to a seventeenth aspect of the application, there is provided a product packaging apparatus substantially as described in the tenth aspect, wherein the controller is further programmed to:

[0047] actuate the retaining device to a clamping position to grip the tube about the closed end and deform the cross-sectional shape of the tube such that the first product item is prevented from entering a space at the closed end of the tube.

[0048] According to an eighteenth aspect of the application, there is provided a product packaging apparatus substantially as hereinbefore described, wherein the controller is further programmed to:

[0049] control the robotic positioning apparatus to rotate the end effector from the inverted orientation to an upright orientation to position the open end of the tube uppermost and to move the end effector to a release area; and

[0050] actuate the retaining device to a disengaged position to release the tube.

[0051] According to a nineteenth aspect of the application, there is provided a product packaging apparatus substantially as hereinbefore described, the apparatus comprising a separation unit to space the product items apart and to present the spaced product items or item groupings to the accessible envelope of the robotic positioning apparatus.

[0052] According to a twentieth aspect of the application, there is provided a product packaging apparatus substantially as hereinbefore described, wherein the separation unit spaces product items / product groupings in a two-dimensional array.

[0053] According to a twenty-first aspect of the application, there is provided a product packaging apparatus substantially as hereinbefore described, wherein the separation unit comprises a conveyor configured to present the product items / product groupings in a manner to conform to the accessible envelope of the robotic positioning apparatus.

[0054] According to a twenty-second aspect of the present application there is provided a product packaging apparatus substantially as hereinbefore described wherein in step i) the controller is programmed to control the robotic positioning apparatus to move the end effector vertically above the product item and to move in the conveying direction at the speed of the conveyor such that the end effector is held vertically above the product item.

[0055] According to a twenty-third aspect of the present application there is provided a product packaging apparatus substantially as hereinbefore described wherein the conveyor comprises a continuous loop carrying a plurality of spaced apart holders each adapted to hold a single product item.

[0056] According to a twenty-fourth aspect of the present application there is provided a product packaging apparatus substantially as hereinbefore described wherein the holders are spaced apart in the conveying direction and orthogonal to the conveying direction so as to present the product items in a two-dimensional array.

[0057] According to a twenty-fifth aspect of the present application there is provided a product packaging apparatus substantially as hereinbefore described wherein the apparatus further comprises a sensing device in communication with the controller to sense or detect a data point of each product item, the controller being programmed to:

[0058] store in memory the data point of each product item in association with the respective holder of the partitioned cell holding the product item;

[0059] control the robotic positioning apparatus and the end effector to package each product item based on the data point of each product item.

[0060] According to a twenty-sixth aspect of the present application there is provided a product packaging apparatus substantially as hereinbefore described wherein the holders are formed of a resiliently soft material.

[0061] According to a twenty-seventh aspect of the present application there is provided a product packaging apparatus substantially as hereinbefore described wherein each holder is configured as a cup comprising a side wall extending from a base, wherein an upper end of the wall presents an edge for receiving a product item.

[0062] According to a twenty-eighth aspect of the present application there is provided a product packaging apparatus substantially as hereinbefore described wherein the wall is castellated to have an inner wall portion and an outer wall portion.

[0063] According to a twenty-ninth aspect of the present application there is provided a product packaging apparatus substantially as hereinbefore described wherein the holder comprises a tab extending radially outwardly from the edge and spaced apart around the edge, and wherein a distal end of the end effector contacts the tab when the end effector is moved downwardly to receive a fruit item in the tube.

[0064] According to a thirtieth aspect of the present application, there is provided a product packaging apparatus substantially as hereinbefore described, wherein each holder is a unitary component.

[0065] According to a thirty-first aspect of the present application, there is provided a product packaging apparatus for packaging product items, the apparatus comprising a conveying device having at least one continuous loop arrangement and a plurality of spaced-apart holders attached to the continuous loop arrangement, each holder being adapted to support a single product item, the holders being spaced apart in a longitudinal direction and a transverse direction of the conveying device such that the product items are arranged in a two-dimensional array at discrete locations.

[0066] According to a thirty-second aspect of the present application, there is provided an actuatable mobile element, wherein the actuatable mobile element is made of a soft, elastic material.

[0067] According to a thirty-third aspect of the present application, there is provided an actuatable mobile element substantially as hereinbefore described, wherein the actuatable mobile element is elastically deformable between a first shape when in the retracted position and a second shape when in the extended position.

[0068] According to a thirty-fourth aspect of the present application, there is provided an actuatable mobile element substantially as hereinbefore described, wherein the first shape is circular.

[0069] According to a thirty-fifth aspect of the present application, there is provided an actuatable mobile element substantially as hereinbefore described, wherein the second shape is non-circular or approximately elliptical.

[0070] According to a thirty-sixth aspect of the present application, there is provided an actuatable mobile element comprising a substantially annular central portion, wherein two laterally extending opposing arms are positioned along a central axis of the annular central portion.

[0071] According to a thirty-seventh aspect of the present application, there is provided an actuatable mobile element comprising a substantially annular central portion, wherein two laterally extending opposing arms are positioned along a central axis of the annular central portion, wherein the central annular portion is comprised of two halves, each half being formed along a central axis of the central annular portion, the central axis being orthogonal to the central axis along which the laterally extending opposing loops are positioned.

[0072] According to a thirty-eighth aspect of the present application, there is provided an actuatable moving element comprising a first portion and a second portion, the first and second portions each comprising an arcuate portion and a transverse member extending from each end of the arcuate portion, the first and second portions being diametrically opposite, wherein the transverse member of the first portion is in contact with or adjacent to the transverse member of the second portion.

[0073] According to a thirty-ninth aspect of the present application, there is provided a holder for supporting products in transit for packaging, the holder comprising:

[0074] - a wall(s) that is / are at least partially conical, at least partially tapered or at least partially semicircular when viewed in cross-section; and

[0075] - at least one substantially horizontally outwardly projecting tab, the tab being located on a top edge of the conical or semicircular wall(s);

[0076] wherein the holder is made of a soft, resilient material.

[0077] According to a fortieth aspect of the present application, there is provided a holder substantially as hereinbefore described, wherein there are six horizontally projecting tabs.

[0078] According to a forty-first aspect of the present application, there is provided a holder substantially as hereinbefore described, wherein the wall(s) that is / are at least partially conical, at least partially tapered or at least partially semicircular are truncated.

[0079] According to a forty-second aspect of the present application, there is provided a holder substantially as hereinbefore described, wherein the base of the wall(s) is connected to a base portion.

[0080] According to a forty-third aspect of the present application, there is provided a holder substantially as hereinbefore described, wherein the base portion is substantially annular when viewed from above / below.

[0081] According to a forty-fourth aspect of the present application, there is provided a holder substantially as hereinbefore described, wherein the wall(s) that is / are at least partially tapered or at least partially semicircular are castellated to have inner and outer wall portions connected by a web.

[0082] According to a forty-fifth aspect of the present application, there is provided the use of a robotic positioning apparatus (RPA) to dimensionally position a container for receiving an article to be packaged.

[0083] Preferably, the article is a product item.

[0084] Preferably, the robot positioning device further moves the container to insert the article to be packaged into the container.

[0085] Preferably, the robot positioning device further controls the end effector to enable the article to be packaged to enter the container.

[0086] Preferably, the robot positioning device further controls the end effector to hold the article to be packaged in the end effector.

[0087] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

[0088] Other aspects and advantages of the present application will become apparent from the subsequent description, given by way of example only, and with reference to the accompanying drawings.

[0089] Definitions

[0090] Hereinafter, the term "robot" shall be understood to mean a manipulator or industrial robot having one or more joints, which robot is in particular capable of performing translational and / or rotational movements, such that one or more end effectors of the robot have different positions (spatial positions or positions). The translational and / or rotational movements can comprise movements along one or more tracks along which parts / arms (links) of the robot are guided. Thus, even such tracks form joints in the sense of kinematic chains, which describe the possibilities of movement of the robot. The term "robot" as used herein can be understood to mean a device comprising a Cartesian robot / gantry robot, a SCARA robot / horizontal articulated robot, a cylindrical robot / cylindrical coordinate robot, a spherical robot / spherical coordinate robot, an articulated robot. Generally, the term "robot" or "robot positioning device" as used herein can be understood to mean a device configured to move with at least four degrees of freedom, comprising three degrees of translational freedom and at least one degree of rotational freedom.

[0091] The term "soft" as used herein refers to the ability of a material to yield to physical pressure.

[0092] The term "elastic" as used herein refers to the ability of a material to recover its original shape after having been deformed due to an applied force. BRIEF DESCRIPTION OF DRAWINGS

[0093] Other aspects of the application will become apparent from the subsequent description, which is given by way of example only and with reference to the accompanying drawings, in which:

[0094] Figure 1An end effector for holding a tubular container in an inverted orientation is shown. The holding device is configured to be coupled to an end effector of a robot arm;

[0095] Figure 2 A holding device is shown Figure 1 in a side view;

[0096] Figure 3 An end effector is shown Figure 1 in another side view, viewed at 90 degrees relative to Figure 2 in a view;

[0097] Figure 4 A longitudinal cross-sectional view is shown along the line A-A shown in Figure 2

[0098] A transversal cross-sectional view is shown along the line B-B shown in Figure 5 Figure 2 A transversal cross-sectional view is shown along the line C-C shown in

[0099] Figure 6 Figure 2 A robot arm and an end effector forming part of a packaging assembly are shown;

[0100] Figure 7 A longitudinal cross-sectional view and a side view of the end effector of

[0101] Figure 8 A longitudinal cross-sectional view and a side view of the end effector of Figure 1 holding an apple within a tubular container, wherein the end effector is positioned above a second apple to be received within the tubular container held by the end effector when moved in the direction of the arrow shown;

[0102] Figure 9 A longitudinal cross-sectional view and a side view of the end effector of Figure 1 holding two apples within a tubular packaging, wherein the holding device is positioned above a third apple to be received within the tubular container held by the end effector when the end effector is moved in the direction of the arrow shown;

[0103] Figure 10 A longitudinal cross-sectional view and a side view of the end effector of Figure 1 wherein the tubular packaging held within the holding device is filled with apples;

[0104] Figure 11 A longitudinal cross-sectional view and a side view of the end effector of Figure 1 wherein the tubular packaging held within the holding device is filled with apples;

[0105] Figure 12 A holding device is shown as shown on the left-hand side​​Figure 1 The end effector rotates as indicated by the arrow to orient the top of the opening of the tubular package as shown on the right-hand side at the top.

[0106] Figure 13 It shows Figure 1 The longitudinal cross-sectional view and side view of the end effector, wherein the full tubular package is oriented with its opening top positioned at the top, in preparation for the holding device to release the full package;

[0107] Figure 14 The diagram shows a longitudinal cross-sectional view and a side view of the full tubular package when it is fully filled.

[0108] Figure 15 This is a partially exploded view of a product packaging apparatus or system according to another preferred embodiment of the present invention;

[0109] Figures 16 to 21 It shows the result of Figure 15 The separation operation performed by the separation unit of the product packaging device;

[0110] Figure 22 A perspective view, top view, side view, and cross-sectional view of a holder for holding a single product article according to a preferred embodiment of another aspect of the present invention are shown. Detailed Implementation

[0111] Figures 1 to 7 An end effector 1 is shown, which is used to hold an elongated container or tube 2 with a top opening in an inverted orientation for packaging articles, such as fruits or vegetables, including apples and tomatoes, and other product articles (referred to herein as products or product articles).

[0112] End effector 1 is adapted to be attached to, for example Figure 7 The end effector of the robot positioning device shown.

[0113] like Figure 7 As shown, a portion of a packaging assembly 4 is illustrated, which includes at least one positioning device in the form of an articulated robotic arm 3 and an associated end effector 1.

[0114] The articulated robotic arm 3 is able to move the end effector in 3D space.

[0115] See again Figures 1 to 6 The end effector 1 includes a frame 5 for receiving the tubular container 2. The frame 5 is preferably open at both ends. In the illustrated embodiment, the frame 5 is constructed as a cylindrical body. The cylindrical body is substantially closed on its longitudinal sides. Figure 2 As shown, the end effector 1 includes a longitudinal window 8 located on one side.

[0116] The frame can be constructed in other ways, for example as a cage formed from a series of longitudinal members held together by one or two or more transverse rings.

[0117] A coupling 6 is provided on the outside of the frame 5 to attach the end effector to a robotic positioning device. This coupling is preferably a quick release coupling and can be a known standard coupling.

[0118] The frame 5 has a hole for receiving the tubular container 2. The internal dimensions (e.g. diameter) of this hole are slightly larger than the external lateral dimensions (diameter) of the tubular container. As Figure 2 shown, when the frame 5 is arranged vertically, the container 2 can also be held in this frame in an upright configuration, with the longitudinal axis A-A of the container being substantially vertical (e.g. as Figure 4 shown).

[0119] As Figure 5 shown, the retaining device comprises a pair of diametrically opposed movable members in the form of rams 10a which are actuatable via pneumatic cylinders 10 between an extended position and a retracted position.

[0120] In the disengaged position, the rams 10a are each out of contact with the opposite sides of the tube 2. In the engaged position, the rams 10a are moved to engage the opposite sides of the tube and deform the cross-sectional shape of the tube by pressing together. Retaining devices which deform the cross-sectional shape of the tubular container 2 near or adjacent the closed end of the tube 2 can help to frictionally secure the relative position of the fruit within the tubular container during the packaging operation as more fruit is introduced into the tube.

[0121] Alternative retaining devices can comprise a single movable member 9 which is adapted to engage and press against the tube against the side of the frame opposite the movable member 9.

[0122] The end effector 1 also has at least one actuatable moving element 7 adjacent one end of the frame. In the case where the tubular container is received in the frame, the actuatable moving element is located on the end effector 1 so as to be adjacent the open end of the tubular container 2.

[0123] The actuatable moving element 7 has two opposing portions 7a, 7b made of a soft, resilient material - see Figure 6 .

[0124] As can be seen, each portion 7a, 7b has an arcuate central section with a lateral member 7La, 7Lb extending radially outwardly from the convex side of the arcuate central section.

[0125] The portions 7a, 7b are diametrically opposite and are shown in an extended (open) position in which the arc-shaped central segments form a substantially circular shape (annular shape).

[0126] The circumference of the annular shape is substantially the same as or slightly larger than the circumference of the tube. Thus, in this extended position, the end effector 1 enables the tube to receive apples or other product items.

[0127] The actuable moving element 7 and the portions 7a, 7b are moved by a pneumatic cylinder 9 and associated plug 9a between:

[0128] - Figure 6 the illustrated extended (open) position; and

[0129] - Figure 8 the illustrated retracted (closed) position, seen from the side;

[0130] In the extended position, by retracting the plug 9a in the direction indicated by the arrow Y in the middle, Figure 6 the proximal ends of the lateral members 7La, 7Lb are moved towards each other.

[0131] This retraction of the plug 9a has the effect of deforming the annular shape formed by the central arc-shaped segments of the portions 7a, 7b into an elliptical shape, which, due to its narrower dimension, extends over the opening of the tube 2 to retain the apples therein.

[0132] Figure 8 and Figure 11 The actuable moving element 7 is shown in the retracted (closed) position. In the closed position, the element 7 extends at least partially over the end of the tube 2 to the extent that it can retain a fruit item within the tube 2 when the latter is lifted with the tube 2 upside down with the opening top facing downwards.

[0133] Thus, in the retracted position, the actuable moving element 7 prevents product items such as apples from passing through the open end of the tubular container 2.

[0134] It will be appreciated that in some embodiments, the actuable element 7 can be moved between the retracted and extended positions without deforming.

[0135] The lateral members of the portions 7a, 7b are received in recesses in the side walls of the frame 5, as Figure 11 illustrated.

[0136] As mentioned above, preferably the actuatable moving element 7 is formed of a soft, resilient material. For example, the actuatable moving element is formed of a polyhydroxy-butyrate-valerate (PHBV) biopolymer such as manufactured and sold by Tianan Biologic Materials Co. Ltd under the trademark ENMAT. The material is selected to provide a relatively soft and resilient contact with the surface of the fruit, thereby avoiding or reducing the risk of damaging the fruit.

[0137] Packaging operation

[0138] With reference to Figures 8 to 14 A packaging operation is described. The packaging operation is performed with the end effector 1 attached to a robot arm 3 or other robot positioning device (not shown).

[0139] The robot positioning device 3 provides at least four degrees of freedom of movement, such that the robot positioning device is adapted to move the end effector in x, y and z translational directions to position the end effector in 3-dimensional space, and includes at least one rotational direction (e.g. roll) to allow the end effector to be inverted about a horizontal axis. The x direction can be a horizontal direction, the y direction can be a horizontal direction orthogonal to the x direction, and the z direction is vertical.

[0140] At the start of the packaging operation, the tubular container 2 is received in the end effector 1.

[0141] For example, the robot arm 3 or other robot positioning device can move the end effector 1 to a tube dispenser (not shown) to receive a tube from an upper or lower end of the frame 5.

[0142] Alternatively, a person can insert or place a tubular container into the frame 5.

[0143] The tubular container 2 is received in the frame 5 of the end effector 1 with the closed (bottom) end of the tubular container uppermost, i.e. the container is held by the robot positioning device in an inverted orientation with the open top of the container facing downwards.

[0144] The robot positioning device moves the inverted tube 2 in the end effector 1 / frame 5 in 3-dimensional space to a product item, e.g. an apple A, supported on a support surface.

[0145] The robot positioning device orients the end effector 1 / frame 5, and thus the tubular container 2, vertically and positions the frame 5 directly above the product item A. With the open end of the tubular container 2 positioned directly above the product item A, the robot positioning device 3 lowers the end effector 1 over the product item A to receive the product in the open end of the tubular container 2, as Figure 8 illustrated.

[0146] Once the product item A is received in the tubular container 2, the actuatable moving element 7 is actuated to the retracted position to capture and hold the product item A in the tubular container 2 within the end effector.

[0147] The robot positioning device then lifts the end effector 1 to pick up the fruit from the support surface S (shown in Figure 7 and moves the end effector to position the end effector 1 directly above a second or further product item, as shown in Figure 9 .

[0148] By lowering the end effector 1 onto the second product item, the end effector 1 picks up the second product item. When the end effector is lowered to the height of the second product item, the actuatable moving element 7 moves to the extended (closed) position to prevent the first product item from falling out of the frame 5 of the end effector 1 once the first product item is in contact or adjacent to the second product item.

[0149] The robot positioning device 3 continues to lower the end effector 1 until the second product item is received in the tubular container 2 - see Figure 10 . When the second product item enters the tubular container 2, the second product item displaces the first product item further into the container 2.

[0150] Once the second product item is received in the tubular container 2, the actuatable moving element 7 can be actuated to the retracted position to hold the second product item and the first product item in the tubular container 2. The robot positioning device 3 then lifts and moves the end effector 1 down to pick up another product item.

[0151] The robot positioning device with the end effector 1 continues to pick up another product item in this way until the tubular container is full, as shown in Figure 11 .

[0152] When full, the tubular container 2 receives five apples A, as shown in Figure 11 .

[0153] Figure 11 The actuatable moving element 7 is shown in the retracted position to hold the lowermost apple and thus all the apples within the tubular container 2.

[0154] The robot positioning device 3 with the end effector 1 then lifts the last product item from the support surface S and the robot positioning device 3 rotates the end effector 1 as shown by the arrow in Figure 12 to position the open top of the tubular container directly above the uppermost apple, as shown in Figure 13 .

[0155] Preferably, the end effector 1 has a holding device configured to grip the inverted tubular container as described above.

[0156] During this process, the holding device 10 continues to deform the cross-sectional shape of the tubular container 2 near the closed end of the tubular container 2. This helps to ensure that the product items A do not substantially fall or move into the space at the end of the container along the tubular container 2. The inverted orientation of the tubular container from the open top facing downwards is corrected or twisted to an upright orientation with the open top uppermost.

[0157] The holding device slightly clamps the tubular container 2 via the pneumatic cylinder 10 and the plug 10a, such that the product items A are substantially held between the holding device 10 and the actuatable moving element 9 - during rotation, the clamping helps to:

[0158] ensure that the uppermost product items in the tube are prevented / restricted from entering the space at the closed end of the tube to prevent potential damage to said product items - i.e. the risk of product items being damaged / scuffed when rotating the end effector from the inverted orientation to the upright orientation.

[0159] Furthermore, such clamping can prevent the products from rolling or moving along the tubular packaging when the end effector is rotated and prevent the products from becoming misaligned within the tubular container - i.e. the desired orientation of the product items can be maintained.

[0160] For example, product items such as apples can be presented on a surface with the stem of the fruit facing downwards relative to the end effector. The holding device 10 ensures that the fruit stem is presented upwards in the tubular container. Other orientations can be desired, for example, presenting the red on the fruit towards a display window of the tubular container.

[0161] The robotic positioning apparatus 3 moves the end effector 1 to a release area to release the tubular container from the end effector.

[0162] Once the tubular container 2 is in the upright orientation, the holding device 10 is actuatable to a disengaged position to release the tube 2 from its clamped configuration and allow the products to controllably drop to rest on the closed bottom of the tubular container 2.

[0163] The robotic positioning apparatus 3 then lifts the end effector 1 away from the tubular container 2 due to the disengagement of the holding device 10, as Figure 13 indicated by the arrow in

[0164] Figure 14 A tubular container 2 filled with apples is shown. A lid can be applied to the open top of the container to complete the packaging operation.

[0165] The skilled person will appreciate that a controller, for example a programmable logic controller (PLC), is provided to control the movement of the robotic positioning apparatus 3 and the actuation of the plugs 9a, 10a. Control lines are provided from a power supply to the actuators 9, 10, for example pneumatic lines from a pressurised pneumatic supply, which is controlled by a control valve, which in turn is controlled by the controller.

[0166] The controller can be internal or external to the robotic positioning apparatus.

[0167] Figure 15 A partial exploded view of a product packaging apparatus or system 100 is provided. The product packaging apparatus comprises at least one robotic positioning apparatus 3 and an end effector 1 as described above (not shown) and a separation unit 101 for separating products provided to the product packaging apparatus 4. Figure 15

[0168] The separation unit 101 separates the products (not shown) to space the products apart at least in a line or row.

[0169] In the embodiment shown, the separation unit separates the products to space the products apart in two dimensions, i.e. in a two-dimensional array. The product items are spaced apart in the x-direction and the y-direction as shown by the holes 150 in the conveyor 151.

[0170] For each of the at least one robotic positioning apparatus 3 with an end effector 1, the separated products are presented to an accessible envelope (accessible region) such that the products can be packaged in tubular packaging held in the end effector 1 as described above.

[0171] The products are spaced apart on the conveying surface sufficiently such that the end effector 1 can be lowered over a single product item without contacting an adjacent product item.

[0172] Figures 15 to 22 The separation operation performed by the separation unit 101 is shown. As Figure 16 shown, the products (apples in the example shown) are provided to the separation unit from a feed conveyor 102.

[0173] The feed conveyor 102 conveys the products towards a passage barrier 103 to separate the products into at least a column or row of products, and preferably into a plurality of adjacent rows of products as shown.

[0174] The feed conveyor 102 can comprise one or more conveying apparatuses to move the products in a conveying direction. In the embodiment shown, the feed conveyor is a conveyor belt.

[0175] ​The products continue to be conveyed on the infeed conveyor 102 along the lanes defined by the lane dividers 103 towards the singulating device 104, which includes the lane dividers 103 and the movable stop block 105 Figure 17 ) to space the product items apart in the longitudinal or conveying direction (y direction) of the singulating unit 101.

[0176] The product items continue along the lanes defined by the lane dividers 103 until they reach the stop block 105, as shown in Figure 17 .

[0177] Once the product items contact or are adjacent to the stop block 105, the stop block 105 is lowered to receive the products on its upper surface, as shown in Figure 18 .

[0178] The stop block is then raised to lift the products above the ramp surface 106 on the downstream side of the stop block 105, as shown in Figure 19 .

[0179] The upper surface of the stop block 105 slopes downwardly towards the downstream ramp surface 106, such that when in the raised position, the individual product items move along the stop block and ramp surface to be received on the holding members or holders 108, as shown in Figure 20 and Figure 21 .

[0180] In the illustrated embodiment, the singulating device includes a stop baffle 107. The baffle 107 contacts the product items as they move along the ramp surface 106, such that the product items are received in the holders 108 in a controlled manner.

[0181] Prior to contacting the product items, the baffle 108 is held in a fixed or initial position, for example as shown in Figure 19 . As the product items move along the ramp surface 106, the products contact the baffle 107, as shown in Figure 20 and Figure 21 , and move the baffle away from the fixed or initial position to allow the products to continue to move along the ramp and onto the holders 108. The baffle can be flexible, or can be movably mounted, for example on a pivot. Preferably, the baffle is biased to the fixed or initial position, and provides a light touch on the products to prevent damage to the products. Other devices can be provided to separate or space the products into one or more spaced apart columns or rows.

[0182] In the illustrated embodiment, the singulating unit 101 also includes a singulating conveyor 109. The singulating conveyor includes a continuous conveyor loop or belt 110 (see Figure 21 ) that carries the holders 108.

[0183] The holders 108 are spaced apart in the conveying direction along the conveyor 110. In the illustrated embodiment, the singulating conveyor comprises holders 108 that are spaced apart in the conveying direction along the conveyor 110 and that are transverse to the conveying direction to be spaced apart in two dimensions, presenting the product items in a two-dimensional array to the robotic positioning device and end effector.

[0184] Each holder holds a single individual product item and represents a position on the conveyor (or in the two-dimensional array). In Figure 21 In the illustrated embodiment, only a small number of holders 108 are shown, however the skilled person will appreciate that the illustrated singulating conveyor will have many more holders located at Figure 15 In the illustrated embodiment, only a small number of holders 108 are shown, however the skilled person will appreciate that the illustrated singulating conveyor will have many more holders located at

[0185] Once the product items are received in the respective holders, the products are singulated and ready to be picked up by the robotic positioning device 3 to be received in the tube carried by the end effector 1 as described above.

[0186] The products are sufficiently spaced apart that the end effector 1 can be lowered over a single product item without contacting adjacent product items.

[0187] The robotic positioning device 3 is controlled to position the end effector 1 vertically above the product items in an inverted position and to move at the speed of the conveyor in the conveying direction (y) so that as the robotic positioning device 3 moves the end effector 1 vertically downwards over the product items, the end effector 1 remains vertically above the product items to receive the product items in the end effector 1.

[0188] Once received in the end effector 1, the robotic positioning device 3 lifts the fruit item from the holder 108 while still moving in the conveying direction at the speed of the conveyor 109. Once received in the end effector and lifted from the holder, the robotic positioning device 3 is controlled to move to position the end effector 1 over the next product item to be packaged and to repeat the vertical movement downwards then upwards while moving simultaneously in the conveying direction.

[0189] In the packaging operation, the product items can not be packaged before reaching the end of the singulating conveyor 109. Any product items that reach the end of the conveyor can be collected and returned to the infeed conveyor 102 to be singulated again for packaging. The product items can be collected in a container and returned to the infeed conveyor by a person for example.

[0190] Figure 22One embodiment of a retainer 108 is shown. The retainer 108 is formed from a soft, resilient material so that the product articles are received on the retainer 108 without being damaged. The resilient material can be silicone rubber or other suitable resilient material. The retainer is a unitary member (single component), for example a unitarily moulded member.

[0191] The retainer 108 is configured as a cup having an upper edge 120 on which the individual product articles are placed. In the embodiment shown, the cup comprises a side wall 121 extending from a base 122, and the upper end of the wall presents an edge 120 for receiving the product articles. The product articles can contact the inner surface or edge on the upper region of the wall 121. The base 122 is attached to the continuous conveyor 110.

[0192] In the embodiment shown, the wall 121 is frusto-conical, however other shapes are possible, for example cylindrical. The wall 121 is castellated to have an inner wall portion 123 and an outer wall portion 124. This form has a web 125 between the inner and outer wall portions, thus a longer wall for a given product size, to help provide a soft and resilient cushion for receiving the product articles. The embodiment shown also has a tab 126 extending radially outwardly from the edge 120. The tab 126 also helps to provide a soft and resilient cushion for receiving the product articles.

[0193] The retainer 108 also has an outwardly projecting circumferential flange 127 at which the wall 121 and the base 122 meet, which helps to support the product within the retainer.

[0194] As Figure 8 and Figure 11 shown, as the end effector 1 is moved downwardly to receive the product article in the tube, the end of the end effector 1 contacts the tab 126. This contact can define a height at which the actuatable element 7 is moved to the retracted position.

[0195] The retainer 108 is configured so that the product article is located high enough on the retainer 108 so that the product article is received within the end effector 1 with the widest peripheral portion of the product article below the actuatable element 7, so that when the actuatable element 7 is moved to the retracted (closed) position, the product article is captured within the tube 2 above the actuatable element 7.

[0196] As mentioned above, to help ensure that the product is not scratched or otherwise damaged during the packaging operation, the retainer 108 is made from a resiliently soft material.

[0197] Preferably, the holders 108 can be made of a polyhydroxy-butyrate-valerate (PHBV) biopolymer such as manufactured and sold by Tianan Biologic Materials Co. Ltd under the trademark ENMAT. The PHBV biopolymer is bio-based and biodegradable.

[0198] The packaging apparatus 100 includes a sensor arrangement 111 Figure 15 to sense or detect each of the partitioned product items. The apparatus 100 also includes a controller with memory in communication with the sensor arrangement, and the controller is configured to store in the memory a data point for each product item associated with the respective holder 108 holding the product item.

[0199] In a preferred embodiment, the partition unit 101 presents the product items in a two-dimensional array, and the controller stores in the memory a data point for each location in the two-dimensional array. Each location can be represented by x, y coordinates. The controller can track or update the x, y coordinates as the conveyor moves the partitioned products in the conveying direction.

[0200] The robotic positioning device 3 moves the end effector 1 over the holder 108 to collect the product item based on the data point for the product item associated with the holder.

[0201] The data point can be a binary indicator to indicate the presence or absence of the product item on the holder 108. If the data point indicates the presence of the product item, the controller controls the robotic positioning device 3 to move the end effector 1 to the holder 108 to pick up the product item.

[0202] The application can also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features.

[0203] Aspects of the application are described by way of example only and it is to be appreciated that modifications and additions can be made thereto without departing from the scope of the application as defined in the appended claims.

Claims

1. An end effector suitable for being carried by a robotic positioning device for packaging product articles, said end effector being adapted to hold a top-opening tube in an inverted orientation during use, wherein, The tube has a closed bottom end and an open top end; The end effector includes: At least one actuable movable element is located on the end effector so as to be adjacent to the tip of the opening of the tube held by the end effector; The actuable movable element is configured to operate between the following positions: An extension position, the extension position extending at least partially above the tip of the opening of the tube held by the end effector, to at least partially block the tip of the opening of the tube to retain the product article in the tube; and The retracted position allows the top of the opening in the tube to be open, enabling the product article to be received into the tube. The tube itself is packaging used to contain the product.

2. The end effector according to claim 1, wherein, The end effector includes a frame for receiving the tube.

3. The end effector according to claim 2, wherein, The actuable movable element is positioned adjacent to one end of the frame.

4. The end effector according to any one of claims 1 to 3, wherein, The actuable movable element is made of a soft, elastic material and is capable of elastic deformation between a first shape in the extended position and a second shape in the retracted position.

5. The end effector according to claim 4, wherein, The first shape is circular.

6. The end effector according to claim 4, wherein, The second shape is non-circular.

7. The end effector according to any one of claims 1 to 3, wherein, The actuable moving element is annular or has an annular central portion.

8. The end effector according to claim 7, wherein, The actuable movable element includes a first part and a second part, each of the first part and the second part including an arcuate portion and a transverse member extending from each end of the arcuate portion, the first part and the second part being diametrically opposed, wherein the transverse member of the first part is in contact with or adjacent to the transverse member of the second part.

9. The end effector according to claim 8, wherein, In the retracted position, a gap is provided between the proximal ends or radially inward portions of the transverse members of the first and second portions, and in the extended position, the arcuate portion elastically deforms, and the proximal ends of the transverse members of the first and second portions move together to close the gap.

10. The end effector according to any one of claims 1 to 3, wherein, The end effector includes: A retaining device, wherein the retaining device is configured as follows: Clamp the tube and secure the tube to the end effector; and The retaining device clamps the tube near the closed bottom end of the tube.

11. The end effector according to claim 10, wherein, The retaining device includes at least one movable part that can move between a disengaged position and an engaged position, wherein in the disengaged position the movable part is not in contact with the tube, and in the engaged position the movable part contacts the tube to compress and deform the tube.

12. The end effector according to claim 4, wherein, The second shape is elliptical.

13. A product packaging apparatus, the product packaging apparatus comprising a robot positioning device and an end effector according to any one of claims 1 to 12, wherein, The robot positioning device provides at least four degrees of freedom to move the end effector relative to the product item to be packaged along the x, y, and z axes and to rotate the end effector about a horizontal axis between inverted and upright orientations.

14. The product packaging apparatus according to claim 13, wherein the product packaging apparatus includes a controller, the controller being programmed to: i) Control the robot positioning device to vertically position the end effector in an inverted orientation above the first product article to be packaged in the x and y directions; and move the end effector vertically downward to receive the first product article into the tube within the end effector; and ii) If necessary, actuate the operable movable element from the retracted position to the extended position to receive the first product article in the tube, and then, once in the tube, actuate the operable movable element to the retracted position to retain the first product article in the tube; and iii) Control the robot positioning device to move the end effector vertically upward.

15. The product packaging apparatus according to claim 14, wherein, The controller is also programmed to: iv) Control the robot positioning device to move the end effector in the x and y directions to vertically position the end effector above another product item, and move the end effector vertically downward to position the next product item adjacent to or in contact with the other product item; v) Actuate the actuable movable element from the retracted position to the extended position; vi) Control the robot positioning device to continue moving the end effector vertically downward to receive the other product item into the tube within the end effector; vii) Actuate the actuable movable element from the retracted position to the extended position to retain the first product article and the other product article in the tube; as well as viii) Control the robot positioning device to move the end effector vertically upward; and ix) Repeat steps iv to viii until the tube is full.

16. The product packaging apparatus according to claim 15, wherein, The controller is also programmed to: x) When the tube is full, control the robot positioning device to rotate the end effector from the inverted orientation to the upright orientation to position the top of the tube opening at the top, and move the end effector to the release area to release the tube from the end effector.

17. The product packaging apparatus according to claim 16, wherein, The controller is also programmed to control the robot positioning device to move the end effector vertically upward to release the tube from the end effector.

18. The product packaging apparatus according to any one of claims 14 to 17, wherein, The end effector includes: a retaining device configured to clamp the tube and secure the tube to the end effector; and wherein the retaining device clamps the tube adjacent to the closed bottom end of the tube. The controller is further programmed to: The retaining device is actuated to the engaged position to clamp the tube near the closed bottom end of the tube and deform the cross-sectional shape of the tube such that the first product article is prevented from entering the space at the closed bottom end of the tube.

19. The product packaging apparatus according to claim 18, wherein, The controller is also programmed to: The robot positioning device is controlled to rotate the end effector from the inverted orientation to the upright orientation, so as to position the top of the tube opening at the topmost position, and to move the end effector to the release area; as well as The retaining device is actuated to the disengaged position to release the tube.

20. The product packaging apparatus according to any one of claims 14 to 17, wherein, The product packaging device includes a separating unit to separate the product items and to present the separated product items or product items in groups to the accessible envelope of the robot positioning device.

21. The product packaging apparatus according to claim 20, wherein, The separating unit groups the product items / products into two-dimensional arrays.

22. The product packaging apparatus according to claim 20, wherein, The separating unit includes a transmitter configured to present the product items / product groups in a manner consistent with the accessibility envelope of the robot positioning device.

23. The product packaging apparatus according to claim 22, wherein, In step i), the controller is programmed to control the robot positioning device to move the end effector vertically above the product item and in the conveying direction at the speed of the conveyor, such that the end effector is held vertically above the product item.

24. The product packaging apparatus according to claim 22, wherein, The conveyor includes a continuous loop carrying a plurality of spaced-apart holders, each holder being adapted to hold a single product item.

25. The product packaging apparatus according to claim 24, wherein, The retainers are spaced apart in the transport direction and orthogonal to the transport direction so as to present the product items in a two-dimensional array.

26. The product packaging apparatus according to claim 24, wherein, The product packaging device also includes sensing devices that communicate with the controller to sense or detect data points for each product item, the controller being programmed to: Data points for each product article associated with the corresponding holder of the partition unit that holds the product article are stored in the memory; The robot positioning device and the end effector are controlled based on the data points of each product item to package each product item.

27. The product packaging apparatus according to claim 24, wherein, The retainer is formed of a flexible soft material.

28. The product packaging apparatus according to claim 24, wherein, Each retainer is configured as a retainer including a sidewall extending from the base, wherein the upper end of the wall presents an edge for receiving product articles.

29. The product packaging apparatus according to claim 28, wherein, The wall is crenellated, having an inner wall portion and an outer wall portion.

30. The product packaging apparatus according to claim 28, wherein, The retainer includes tabs extending radially outward from the edge and spaced apart around the edge, wherein the end of the end actuator contacts the tabs when the end actuator moves downward to receive the product article in the tube.

31. The product packaging apparatus according to claim 24, wherein, Each retainer is a single integral component.

32. A product packaging apparatus for packaging products, the product packaging apparatus comprising: A robot positioning device, the robot positioning device comprising an end effector according to any one of claims 1 to 12; A conveying device having a continuous conveyor belt and a plurality of spaced-apart retainers attached to the continuous conveyor belt, each retainer being configured to have an upper edge for placing a single product article, the retainers being spaced apart in the longitudinal and transverse directions of the conveying device, wherein the retainers are spaced apart along the conveyor belt in the conveying direction and cross the conveyor belt orthogonal to the conveying direction, such that the product articles are arranged in a two-dimensional array at discrete positions, wherein the retainers are formed of a soft, elastic material such that the product articles are received on the retainers without being damaged. Each retainer supports a single product item during transport, such that the single product item can be picked up from the retainer by the tube with the top opening held by the end effector, and simultaneously placed directly into the tube with the top opening.

33. The product packaging apparatus for packaging products and articles according to claim 32, wherein, The retainer is configured such that the product article is placed on the retainer such that when the product article is received in the tube of the top opening held by the end effector, the widest peripheral portion of the product article is above the actuating element of the end effector, so that when the actuating element moves to the closed position, the product article is captured in the tube of the top opening held by the end effector.

34. An automated method for packaging product articles, the automated method comprising the following steps: - The product items are conveyed on a plurality of spaced-apart holders, the holders having an upper edge for holding individual product items; as well as - The product item is picked up from the spaced-out retainer using a tube with a top opening that forms part of the end effector for packaging in the tube with the top opening. The end effector is an end effector according to any one of claims 1 to 12.

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