Universal case sealer with case lifter

Abstract

Various embodiments of the present disclosure provide a universal case sealer including a case lifter configured to lift the case out of engagement with a lower drive element 115 (e.g., a drive belt) of the case sealer when the case reaches a holding position below the top head assembly 400, and thereafter lower the case into engagement with the lower drive element once the top head assembly has descended to within a specified distance of the top surface of the case. In certain embodiments thereof, the case lifter includes a case stopper 215 positioned to prevent the case from moving further below the top head assembly after reaching the holding position.

Description

[0001] priority

[0002] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 171,785, filed April 7, 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to case sealers, and more particularly to a universal case sealer configured for sealing cases of varying heights. Background Art

[0004] Every day, companies around the world pack millions of items into boxes (such as those formed from corrugated cardboard) to prepare them for shipping. Case sealers partially automate this process by applying pressure-sensitive tape and, in some cases, protective liner to already-filled boxes to seal them shut. Universal case sealers (a subset of case sealers) automatically adjust to the height of the box being sealed, allowing them to seal boxes of varying heights.

[0005] A typical universal carton sealer includes a frame including a lower tape cassette and two lower drive belts, a lifting frame mounted to the frame, and a top head assembly movably mounted to the lifting frame and including an upper tape cassette, a pressure switch, and two upper drive belts. The lower tape cassette is configured to apply tape to the front, bottom, and rear surfaces of a box as the upper and lower drive belts move the box past the lower tape cassette, while the upper tape cassette is configured to apply tape to the front, top, and rear surfaces of a box as the upper and lower drive belts move the box past the upper tape cassette.

[0006] In operation, an operator (such as a person or an automatic box feeding system) moves the box into contact with the pressure switch. In response, the actuator begins to raise the top head assembly. Once the top head assembly rises above the box so that the box stops contacting the pressure switch, the operator moves the box to a holding position below the top head assembly. When the box is in the holding position, the bottom surface of the box rests on the lower drive belt. Because the lower drive belt is constantly circulating, the operator must fix the box in the holding position (resisting the tension of the lower drive belt) when the top head assembly is lowered. Once the upper drive belt contacts the top surface of the box, the operator releases the box, and these drive belts move the box relative to the tape cassette, which applies tape to the box.

[0007] Especially with heavy boxes and high-throughput applications, holding the box in the holding position against the pull of the lower drive belt while waiting for the top head assembly to descend can be a difficult task. This can occasionally cause the operator to release the box before the upper drive belt contacts the top surface of the box. This can affect the timing of the carton sealer (such as prematurely triggering sensors that control various functions of the carton sealer) and cause improper sealing and / or damage to the box or the product inside. The same situation can also occur if the operator accidentally pushes the box past the holding position. Summary of the Invention

[0008] Various embodiments of the present disclosure provide a universal case sealer including a case lifter configured to lift a case out of engagement with a lower drive element (e.g., a drive belt) of the case sealer when the case reaches a holding position below a top head assembly, and thereafter lower the case into engagement with the lower drive element once the top head assembly has descended to within a specified distance of the top surface of the case. In certain embodiments thereof, the case lifter includes a case stopper positioned to prevent the case from moving further below the top head assembly after reaching the holding position.

[0009] Certain embodiments of the case sealer include: a frame; a lower drive element; a lower drive element actuator operably connected to the lower drive element and configured to drive the lower drive element; and a box lifter movable relative to the lower drive element between a box-lifting position in which a portion of the box lifter is above a top surface of the lower drive element and a retracted position in which the portion of the box lifter is not above the top surface of the lower drive element. When the box lifter is in the box-lifting position, the portion of the box lifter is oriented to lift a portion of the box above and out of contact with the lower drive element as the box moves onto the box lifter.

[0010] Certain embodiments of a method for operating a case sealer to apply tape to a box include: driving a lower drive element of the case sealer; detecting a box proximate a top head assembly of the case sealer; in response to detecting the box proximate the top head assembly, raising the top head assembly above a top surface of the box; automatically moving the case lifter to lower the portion of the box into contact with the lower drive element once the box is within a specified distance of the top head assembly after a portion of the box has moved onto a case lifter positioned below the top head assembly and holding the portion of the box above and out of contact with the lower drive element; engaging the box with the top head assembly; and moving the box past a tape cassette of the case sealer via the lower drive element to apply tape to the box. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a perspective view of an exemplary embodiment of a case sealing machine of the present disclosure.

[0012] Figure 2 It shows Figure 1 Block diagram of some components of a carton sealing machine.

[0013] Figure 3 yes Figure 1 A perspective view of the base assembly of a case sealing machine.

[0014] Figure 4A and Figure 4B yes Figure 1 A perspective view of the case lifting assembly of a case sealing machine.

[0015] Figure 5A and Figure 5B yes Figure 1 A side view of a portion of a case sealing machine with a case lifter in a case lifting position and a retracted position, respectively.

[0016] Figure 6 yes Figure 1 A three-dimensional view of the top head assembly of a carton sealing machine.

[0017] 7A to 7H yes Figure 1 Various views of the tape cassette (and its components) of a carton sealer.

[0018] Figure 8 is a flow chart illustrating an exemplary box sealing process.

[0019] 9A to 9D yes Figure 1 Figure 7 is a side view of a case sealing machine during an early stage of the case sealing process. DETAILED DESCRIPTION

[0020] Although the systems, devices and methods described herein can be implemented in a number of different forms, the drawings illustrate 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 some embodiments may include additional, different or fewer components. The arrangement and type of components, the shape, size and material of the components, and the manner in which the components are connected may be changed without departing from the spirit or scope of the claims. Unless otherwise stated, any direction mentioned in the specification reflects the orientation of the components shown in the corresponding drawings and does not limit the scope of the present disclosure. In addition, terms related to installation methods (such as coupling, installation, connection, etc.) are not intended to be limited to direct installation methods, but should be broadly interpreted to include indirect and operatively coupled, installed, connected, etc. installation methods. This specification is intended to be regarded as a whole and to be interpreted in accordance with the principles of the present disclosure and as understood by those of ordinary skill in the art.

[0021] Various embodiments of the present disclosure provide a universal case sealer including a case lifter configured to lift a case out of engagement with a lower drive element (e.g., a drive belt) of the case sealer when the case reaches a holding position below a top head assembly, and thereafter lower the case into engagement with the lower drive element once the top head assembly has descended to within a specified distance of the top surface of the case. In certain embodiments thereof, the case lifter includes a case stopper positioned to prevent the case from moving further below the top head assembly after reaching the holding position.

[0022] Figure 1 An example embodiment of a carton sealing machine 10 of the present disclosure is shown. The carton sealing machine 10 includes a base assembly 100, which includes a box lifting assembly 200, a lifting frame assembly 300, a top head assembly 400, an upper tape box 1000a, and a lower tape box 1000b. Figure 2 As shown, the carton sealing machine 10 also includes several actuating assemblies and actuators configured to control the movement of certain components of the carton sealing machine 10; a plurality of sensors S; and control circuits and systems for controlling the actuating assemblies and actuators (as well as other mechanical, electromechanical, and electrical components of the carton sealing machine 10) in response to signals received from the sensors S.

[0023] The case sealing machine 10 includes a controller 90 that is communicatively connected to the sensor S to send and receive signals to and from the sensor S. The controller 90 is operatively connected to the actuating assemblies and actuators to control them. The controller 90 can be any suitable type of controller (e.g., a programmable logic controller) that includes any suitable processing device(s) (e.g., a microprocessor, a microcontroller-based platform, an integrated circuit, or an application-specific integrated circuit) and any suitable memory device(s) (e.g., random access memory, read-only memory, or flash memory). The memory device(s) store instructions that are executable by the processing device(s) to control the operation of the case sealing machine 10.

[0024] The base assembly 100 is configured to align boxes to be sealed, support the lower tape cassette 1000b, and (along with the top head assembly 400) move the boxes through the case sealer 10. The base assembly 100 supports the lift assembly 300 (which in turn supports the top head assembly 400). Figure 3 As best shown in FIG. 1 , the base assembly 100 includes a base assembly frame 111, an infeed table 112, an outfeed table 113, a side rail assembly (not shown), a lower drive assembly 115, and a case lift assembly 200. The base assembly 100 defines the infeed end IN ( Figure 1 ) and the delivery end OUT( Figure 1 ), at the feeding end, an operator (such as a person or an automatic box feeding system) feeds the box to be sealed (via the feeding table 112) into the carton sealing machine 10, and at the feeding end, the carton sealing machine 10 pushes the sealed box onto the feeding table 113.

[0025] The base assembly frame 111 is formed from any suitable combination of solid and / or tubular members and / or plates fastened together. The base assembly frame 111 is configured to support the other components of the base assembly 100.

[0026] The infeed station 112 is mounted to the base assembly frame 111 near the infeed end IN of the case sealer 10. The infeed station 112 includes a plurality of rollers on which an operator can place and fill boxes, which are then used to transport the filled boxes toward the top head assembly 400. The infeed station 112 includes an infeed station sensor S1 ( Figure 2), the feed table sensor S1 can be any suitable sensor (such as a photoelectric sensor) configured to detect the presence of a box on the feed table 112 (more specifically, the presence of a box at a specific location on the feed table 112 corresponding to the location of the feed table sensor S1). In other embodiments, another component of the case sealing machine 10 includes the feed table sensor S1. The feed table sensor S1 is communicatively connected to the controller 90 to send signals to the controller 90 in response to detecting a box (a box detected signal) and subsequently no longer detecting a box (a box not detected signal), as described below.

[0027] A feed-out table 113 is mounted to the base assembly frame 111 near the outfeed end OUT of the case sealer 10. The feed-out table 113 comprises a generally flat surface onto which the cases are pushed after being taped, although in other embodiments the feed-out table may comprise a plurality of rollers.

[0028] The side rail assembly is supported by the base assembly frame 111 near the feed table 112 and includes a first side rail 114a and a second side rail 114b and a side rail actuator 117 ( Figure 2 The side rails 114a and 114b are generally parallel to the direction of travel D of the boxes through the carton sealer 10 ( Figure 1 ) and are movable laterally inward (relative to the direction of travel D) to laterally center the box on the infeed table 112. The side rail actuator 117 is operatively connected to the first side rail 114a and the second side rail 114b (directly or via a suitable linkage) to move the side rails between the following configurations: (1) an idle configuration ( Figure 1 ), in an idle configuration, the side rails are located at or near the lateral extent of the feed table 112 to enable an operator to position a box to be sealed between the side rails on the feed table 112; and (2) a centered configuration (not shown), in which the side rails (after being moved toward each other) contact the box and center the box on the feed table 112. The controller 90 is operably connected to the side rail actuator 117 to control the side rail actuator 117 to move the side rails 114a and 114b between the idle configuration and the centered configuration. The side rail actuator 117 can be any suitable type of actuator, such as a motor or a pneumatic cylinder supplied with pressurized gas and controlled by one or more valves.

[0029] Lower drive assembly 115 is supported by base assembly frame 111 and (along with top drive assembly 420, described below) is configured to move the box in direction D. Lower drive assembly 115 includes first lower drive element 115a and second lower drive element 115b (although in other embodiments it may include only one drive element or more than two drive elements), and lower drive assembly actuator 118 ( Figure 2), the lower drive assembly actuator is operably connected to the first and second lower drive elements 115a, 115b to drive the first and second lower drive elements to move the boxes through the case sealer 10 (together with the top drive assembly 420). In this exemplary embodiment, the lower drive assembly actuator 118 includes a motor that is operably connected to the first and second lower drive elements 115a, 115b via one or more other components (such as sprockets, gears, screws, tensioning elements and / or chains), which in this exemplary embodiment include endless belts. In other embodiments, the lower drive assembly actuator 118 may include any other suitable actuator. In other embodiments, the first and second lower drive elements 115a, 115b may include any other suitable one or more components, such as rollers. The controller 90 is operably connected to the lower drive assembly actuator 118 to control the operation of the lower drive assembly actuator 118.

[0030] The lower drive assembly 115 supports a box entry sensor S3 downstream of the feed stage 112 and the front surface sensor S2 (described below) and below the top head assembly 400 so that the box entry sensor S3 can detect when a box enters the space below the top head assembly 400. As used herein, "downstream" refers to the direction of travel D, and "upstream" refers to the direction opposite to the direction of travel D. Additionally, unless otherwise expressly stated, "above" and "below" as used herein refer to "in the plane above" and "in the plane below," rather than "directly above" or "directly below." The box entry sensor S3 includes a proximity sensor (or any other suitable sensor, such as a mechanical sensor) configured to detect the presence of a box. In other embodiments, the box entry sensor S3 is supported by the lift assembly 300 or the top head assembly 400. The box entry sensor S3 is communicatively connected to the controller 90 to send signals to the controller 90 in response to detecting a box (a box detected signal) and no longer detecting a box (a box not detected signal).

[0031] The base assembly frame 111 supports a box departure sensor S6, which includes a proximity sensor (or any other suitable sensor) configured to detect the presence of a box. Although not shown, the box departure sensor S6 is positioned near the delivery platform 113 (downstream of the box entry sensor S3 and retraction sensor S4 described below) so that the box departure sensor S6 can detect when a box exits from under the top head assembly 400. The box departure sensor S6 is communicatively connected to the controller 90 to send signals to the controller 90 in response to detecting a box (a box detected signal) and no longer detecting a box (a box not detected signal). In other embodiments, the box departure sensor S6 is part of the top head assembly 400.

[0032] The box lift assembly 200 is mounted on the base assembly frame 111 and is configured to lift the box out of engagement with the lower drive elements 115a and 115b when the box reaches a holding position below the top head assembly 400, and then lower the box into engagement with the lower drive elements 115a and 115b once the top head assembly 400 has been lowered to within a specified distance of the top surface of the box. In this exemplary embodiment, the box lift assembly 200 is also configured to prevent any further movement of the box below the top head assembly 400 after the box reaches the holding position. Figure 4A and Figure 4B As best shown in FIG, the box lift assembly 200 includes a box lift 210 , a box lift mounting plate 220 , a box lift mounting pin 230 , a box lift actuator 240 , and a box lift-actuator mounting plate 250 .

[0033] The box lifter 210 includes a body 211 having a generally planar box engagement surface 211a and a box stopper 215 extending from the box engagement surface 211a. The box stopper 215 includes a box engagement surface 215a that is oriented to face the box as it travels toward the box lifter 210 in a direction D. In this exemplary embodiment, the body is L-shaped, but in other embodiments, the body may have any other suitable shape. A box lifter mounting plate 220 is attached to the base assembly frame 111, such as between the first lower drive element 115a and the second lower drive element 115b, via suitable fasteners. The box lifter 210 is pivotally mounted to the box lifter mounting plate 220 via a box lifter mounting pin 230 (e.g., by inserting the box lifter mounting pin through a mounting hole defined by the box lifter 210 and the box lifter mounting plate 220). The box lift actuator 240 is attached, such as via suitable fasteners, to a box lift actuator mounting plate 250. The box lift-actuator mounting plate 250 is attached, such as via suitable fasteners, to the base assembly frame 111 between the first lower drive element 115a and the second lower drive element 115b.

[0034] The box lift actuator 240 is operatively connected to the box lift 210 to move the box lift 210 about the box lift mounting pin 230 and relative to the lower drive assembly 115 in the box lift position ( Figure 5A ) and retracted position ( Figure 5B ). The box lift actuator 240 comprises a pneumatic actuator in this exemplary embodiment, but may comprise any other suitable actuator (e.g., a motor or hydraulic actuator) in other embodiments. In this exemplary embodiment, the box lift 210 is moved away from the box (relative to the box) when pivoting from its box lifting position to its retracted position (and vice versa). Figure 5A and Figure 5B The cam is pivoted counterclockwise from the perspective shown.

[0035] The controller 90 is operably connected to the box lift actuator 240 to control the movement of the box lift 210 between its box lift position and its retracted position. That is, in this exemplary embodiment, the box lift actuator 240 actively moves the box lift 210 from its box lift position to its retracted position, and vice versa. In other embodiments, the box lift actuator is configured to actively move the box lift from its box lift position to its retracted position, or vice versa. In these embodiments, the box lift is biased to the other of the box lift position and the retracted position by a suitable biasing element (e.g., a spring). In these embodiments, the box lift actuator is configured to move the box lift to its unbiased position against the biasing force of the biasing element.

[0036] like Figure 5A As best shown in FIG. , when the box lifter 210 is in the box-lifting position, the box lifter 210 is oriented such that at least a portion of the box-engaging surface 211a of the body 211 and at least a portion of the box-engaging surface 215a of the box stopper 215 are positioned above the upper surfaces of the first and second lower drive elements 115a, 115b. As the box is pushed in the D direction, the body 211 gradually lifts the box above and out of engagement with the first and second lower drive elements 115a, 115b. While the box engages the box-engaging surface 215a, the box stopper 215 prevents the box from further movement beneath the top head assembly 400. At this point, the box is in the holding position. Accordingly, this exemplary embodiment of the box lifter 210, when in the box-lifting position, prevents the box from being pushed past the holding position while maintaining the box out of contact with the first and second lower drive elements 115a, 115b.

[0037] In this exemplary embodiment, when in the box lifting position, the box lifter 210 is oriented to form a non-zero angle α (here, the angle is approximately 9 degrees, but in other embodiments it can be any other suitable non-zero angle) between the box engaging surface 211a and the top surfaces of the first lower drive element 115a and the second lower drive element 115b (both of which are substantially horizontal in this exemplary embodiment). This means that when the box lifter 210 is in the box lifting position, the box engaging surface 211a actually forms a slope. Figure 5B As best shown in FIG, when the box lifter 210 is in the retracted position, the box engaging surface 211 a and the box stopper 215 are positioned so that they are not above (in this exemplary embodiment, below) the upper surfaces of the first and second lower drive elements 115 a, 115 b to enable the first and second lower drive elements to engage and move the box in the D direction.

[0038] The lifting frame assembly 300 is configured to support and control the vertical movement of the top head assembly 400 relative to the base assembly 100. The lifting frame assembly 300 includes a top head actuation assembly 305, which includes one or more top head actuation assembly actuators 310 ( Figure 2), the top head assembly actuator is operably connected to the top head assembly 400 and is configured to move the top head assembly 400 toward and away from the base assembly 100. In this exemplary embodiment, the top head assembly actuator comprises a pneumatic cylinder supplied with pressurized gas and controlled by one or more valves, but in other embodiments, the top head assembly actuator can be any other suitable type of actuator (such as a motor). The controller 90 is operably connected to the top head assembly actuator(s) to control the vertical movement of the top head assembly 400.

[0039] The top head assembly 400 is movably supported by the lift assembly 300 to adjust to boxes of varying heights and is configured to move boxes through the case sealer 10, engaging the top surface of the boxes while doing so, and supporting the upper tape cassette 1000a. Figure 2 and Figure 6 As best shown in FIG, the top head assembly 400 includes a top head assembly frame 410, an upper drive assembly 420, a front surface sensor S2, a case lift sensor S4, an arm retract sensor S5, and a case exit sensor S6. In other embodiments, one or more other components of the case sealer 10 (such as the base assembly 100 and / or the lift assembly 300) include one or more of the sensors S2, S4, S5, and S6.

[0040] The top head assembly frame 410 is configured to mount the top head assembly 400 to the lifting frame assembly 300 and support other components of the top head assembly 400, and is formed from any suitable combination of solid or tubular members and / or plates fastened together. The top head assembly frame 410 includes laterally extending first and second mounting arms 412, 414 to which the top head assembly actuator 310 of the lifting frame assembly 300 is operatively connected.

[0041] The upper drive assembly 420 is supported by the top head assembly frame 410 and (along with the lower drive assembly 115, as described above) is configured to move the box in the direction D. The upper drive assembly 420 includes an upper drive element (or multiple upper drive elements in other embodiments) and an upper drive assembly actuator 422 ( Figure 2), the upper drive assembly actuator is operably connected to the upper drive element to drive the upper drive element, thereby (together with the lower drive assembly 115) moving the boxes through the case sealer 10. In this exemplary embodiment, the upper drive assembly actuator 422 includes a motor that is operably connected to the upper drive element via one or more other components (such as sprockets, gears, screws, tensioning elements and / or chains), and in this exemplary embodiment, the upper drive element includes an endless belt. In other embodiments, the upper drive assembly actuator 422 may include any other suitable actuator. In other embodiments, the upper drive element may include any other suitable one or more components, such as rollers. The controller 90 is operably connected to the upper drive assembly actuator 422 to control the operation of the upper drive assembly actuator 422.

[0042] The front surface sensor S2 comprises a mechanical pedal switch (or any other suitable sensor, such as a proximity sensor) positioned at the front end of the top head assembly frame 410 and configured to detect when the front surface of the case initially contacts (or comes within a predetermined distance of) the top head assembly 400. The front surface sensor S2 is communicatively connected to the controller 90 to send signals to the controller 90 in response to actuation (a signal indicating that a case has been detected) and deactuation (a signal indicating that a case has not been detected) of the front surface sensor S2 (corresponding to the front surface sensor S2 detecting a case and no longer detecting a case and / or object).

[0043] The box lifter sensor S4 comprises a proximity sensor (or any other suitable sensor) configured to detect the presence of a box (particularly, to detect a box within a specified distance of the proximity sensor). Although not shown here, the box lifter sensor S4 is positioned on the underside of the top head assembly frame 410 so that the box lifter sensor S4 can detect when a box reaches a specific position (here, a holding position) below the top head assembly 400. The box lifter sensor S4 is communicatively connected to the controller 90 to send signals to the controller 90 in response to detecting a box (a box detected signal) and no longer detecting a box (a box not detected signal).

[0044] The retraction sensor S5 comprises a proximity sensor (or any other suitable sensor) configured to detect the presence of a box. Although not shown, the retraction sensor S5 is positioned on the underside of the top head assembly frame 410, downstream of the box entry sensor S3, so that the retraction sensor S5 can detect when the box reaches a specific position below the top head assembly 400 (here, just before the box contacts the front roller, as explained below). The retraction sensor S5 is communicatively connected to the controller 90 to send a signal to the controller 90 in response to detecting a box (a "box detected" signal) and no longer detecting a box (a "box not detected" signal).

[0045] The controller 90 is operably connected to: (1) the top head actuation assembly 305 and is configured to control the top head actuation assembly 305 to control the vertical movement of the top head assembly 400 in response to signals received from sensors S2, S3 and S5; and (2) the upper tape cassette 1000a and the lower tape cassette 1000b and is configured to control the force reduction function of these tape cassettes in response to signals received from sensor S4, as described below in conjunction with Figure 8 Described in detail.

[0046] The upper tape cassette 1000a is removably mounted to the top header assembly 400 and is configured to apply tape to the front, top, and rear surfaces of a box. Although not separately depicted, the lower tape cassette 1000b is removably mounted to the base assembly 100 and is configured to apply tape to the front, bottom, and rear surfaces of a box. Figure 2 and 7A to 7H As best shown in FIG. 1 , the tape cassette 1000 includes a first mounting plate M1 that supports a front roller assembly 1100, a rear roller assembly 1200, a cutter assembly 1300, a tape mounting assembly 1400, a tension roller assembly 1500, and a cassette actuation assembly 1600. Figure 7A As best shown in the figure, the second mounting plate M2 is mounted to the first mounting plate M1 via a plurality of spaced shafts and fasteners (not labeled) to partially enclose certain elements of the front roller assembly 1100, the rear roller assembly 1200, the cutter assembly 1300, the tape mounting assembly 1400, the tension roller assembly 1500, and the tape cassette actuation assembly 1600 between the first and second mounting plates.

[0047] The front roller assembly 1100 includes a front roller arm 1110 and a front roller 1120. The front roller arm 1110 is pivoted via a front roller arm pivot PS. 前 The front roller arm 1110 is pivotally mounted to the first mounting plate M1 so that the front roller arm 1110 can be moved relative to the mounting plate M1 about the axis A in the front roller arm extended position ( 7A to 7C ) and the front roller arm retracted position ( Figure 7D) are pivoted between the front roller arm 1110 and the front roller arm 1110. The front roller arm 1110 includes a front roller mounting shaft 1120a, and the front roller 1120 is rotatably mounted to the front roller mounting shaft 1120a, so that the front roller 1120 can rotate relative to the front roller mounting shaft 1120a.

[0048] The rear roller assembly 1200 includes a rear roller arm 1210 and a rear roller 1220. The rear roller arm 1210 is pivoted via a rear roller arm pivot shaft PS. 后 The rear roller arm 1210 is pivotally mounted to the first mounting plate M1 so that the rear roller arm 1210 can be moved relative to the mounting plate M1 around the axis A in the rear roller arm extended position ( 7A to 7C ) and rear roller arm retracted position ( Figure 7D ) The rear roller arm 1210 includes a rear roller mounting shaft 1220a, and the rear roller 1220 is rotatably mounted to the rear roller mounting shaft 1220a, so the rear roller 1220 can rotate relative to the rear roller mounting shaft 1220a.

[0049] A rigid first coupling member 1020 is attached to and extends between the first roller arm 1110 and the second roller arm 1210. The first coupling member 1020 couples the front roller assembly 1100 and the rear roller assembly 1200 so that: (1) moving the front roller arm 1110 from the front roller arm extended position to the front roller arm retracted position causes the first coupling member 1020 to force the rear roller arm 1210 to move from the rear roller arm extended position to the rear roller arm retracted position (and vice versa); and (2) moving the rear roller arm 1210 from the rear roller arm extended position to the rear roller arm retracted position causes the first coupling member 1020 to force the front roller arm 1110 to move from the front roller arm extended position to the front roller arm retracted position (and vice versa).

[0050] Tape cassette actuator assembly 1600 ( Figure 2 ) includes a roller arm actuation assembly 1700 and a cutter arm actuation assembly 1800.

[0051] The roller arm actuation assembly 1700 is configured to move the coupled front roller arm 1110 and rear roller arm 1210 between their respective extended and retracted positions. Figure 7G As best shown in FIG, in this exemplary embodiment, roller arm actuation assembly 1700 includes a support plate 1702 and a roller arm actuator 1710 pivotally attached to support plate 1702 via a pin assembly 1703. Roller arm actuator 1710 may be any suitable actuator, such as a motor or a pneumatic cylinder supplied with pressurized gas and controlled by one or more valves.

[0052] The roller arm actuator 1710 is operably connected to the front roller assembly 1100 to control the movement of the front roller arm 1110 and the rear roller arm 1210 coupled thereto between their respective extended and retracted positions. More specifically, the roller arm actuator 1710 is coupled between the mounting plate M2 and the first roller arm assembly 1100 by attaching the support plate 1702 to the mounting plate M2 and attaching the roller arm actuator 1710 to the shaft 1130 of the front roller assembly 1100.

[0053] The controller 90 is operably connected to the roller arm actuator 1710 and is configured to control the roller arm actuator 1710 and, therefore, the position of the front roller arm 1110 and the rear roller arm 1210 .

[0054] like Figure 7E and Figure 7F As best shown in the figure, the cutter assembly 1300 includes a cutter arm 1301, a cutting device cover pivot 1306, a cutter arm actuator coupling element 1310, a cutting device mounting assembly 1320, a cutting device 1330, a cutting device cover 1340, a cutting device pad 1350, and a rotation control plate 1360, wherein the cutting device 1330 includes a toothed blade (not labeled) configured to cut the tape.

[0055] The cutter arm 1301 includes a cylindrical surface 1301a defining a cutter arm mounting opening. The cutter arm 1301 pivots via a front roller arm axis PS. 前 The bushings 1303a and 1303b are pivotally mounted (via the cutter arm mounting opening) to the first mounting plate M1 so that the cutter arm 1301 can be pivotally moved relative to the mounting plate M1 about the axis A. 前 In the cutter arm extended position ( 7A to 7C ) and the cutter arm retracted position ( Figure 7D ) pivots between.

[0056] The cutter arm actuator coupling element 1310 includes a support plate 1312 and a coupling shaft 1314 extending transversely from the support plate 1312. The support plate 1312 is fixedly attached to the cutter arm 1301 via fasteners 1316 so that the coupling shaft 1314 is generally parallel to the axis A. 前 and is coplanar with the axis.

[0057] The cutting device mounting assembly 1320 is fixedly mounted on the support arm 1310 (e.g., by welding) and is configured to removably receive the cutting device 1330. That is, the cutting device mounting assembly 1320 is configured so that the cutting device can be removably mounted to the cutting device mounting assembly 1320. The cutting device mounting assembly 1320 is described in U.S. Patent No. 8,079,395, but any other suitable cutting device mounting assembly may be used to support the cutting device 1330.

[0058] The cutting device cover 1340 includes a body 1342 and a finger 1344 extending from the body 1342. A pad 1350 is attached to the body 1342. The cutting device cover 1340 is pivotally mounted to the support arm 1310 via a mounting opening (not labeled) and a cutting device cover pivot 1306. Once attached, the cutting device cover 1340 can be pivotally moved relative to the cutter arm 1301 and the cutting device mount 1320 about an axis A. 盖件 The cutting device cover 1340 pivots from front to back and back to front between a closed position and an open position. A cutting device cover biasing element 1346, which in this exemplary embodiment comprises a torsion spring, biases the cutting device cover 1340 to the closed position. When in the closed position, the cutting device cover 1340 generally surrounds the cutting device 1330, such that the pad 1350 contacts the toothed blade of the cutting device 1330. When in the open position, the cutting device cover 1340 exposes the cutting device 1330 and its toothed blade.

[0059] The cutting device cover pivot 1306 is also attached to a rotation control plate 1360. The rotation control plate 1360 includes a slot-defining surface 1362 that defines a slot. The surface 1362 acts as a guide for a bushing (not shown) that is attached to the mounting plate M2. The bushing provides lateral support for the cutter assembly 1300 to substantially prevent the cutter assembly from moving toward or away from the mounting plates M1 and M2 and interfering with other components of the tape cassette 1000 during use.

[0060] The cutter arm actuation assembly 1800 is configured to move the cutter arm 1301 between a retracted position and an extended position. Figure 7H As best shown in FIG, in this exemplary embodiment, cutter arm actuation assembly 1800 includes a cutter arm actuator 1810. Cutter arm actuator 1810 may be any suitable actuator, such as a motor or a pneumatic cylinder supplied with pressurized gas and controlled by one or more valves.

[0061] The cutter arm actuator 1810 is operably connected to the cutter assembly 1300 to control the movement of the cutter arm 1301 from its retracted position to its extended position. More specifically, the cutter arm actuator 1810 is coupled between the mounting plate M1 and the cutter assembly 1300 via a coupling shaft 1314 attached to the shaft 1610 and to the cutter arm actuator coupling element 1310.

[0062] The controller 90 is operably connected to the cutter arm actuator 1810 and is configured to control the cutter arm actuator 1810 and, therefore, the position of the cutter arms 1110 and 1301 .

[0063] The tape installation assembly 1400 includes a tape installation plate 1410 and a tape core installation assembly 1420 rotatably mounted to the tape installation plate 1410. The tape core installation assembly 1420 is further described in U.S. Patent No. 7,819,357, the entire contents of which are incorporated herein by reference (although other tape core installation assemblies may be used in other embodiments). A tape roll R may be mounted to the tape core installation assembly 1420.

[0064] Tension roller assembly 1500 includes several rollers (not labeled) rotatably mounted on shafts supported by first mounting plate M1. The free end of a tape roll R mounted on tape core mounting assembly 1420 can be threaded through the rollers until the free end is adjacent to front roller 1120 of front roller assembly 1110 with its adhesive side facing outward, ready for attachment to a box. Tension roller assembly 1500 is further described in U.S. Patent No. 7,937,905 (although other tension roller assemblies may be used in other embodiments).

[0065] Now see Figure 8 (This figure shows the box sealing process 2000) and 9A to 9D (These figures show the case sealing machine 10 during the early stages of the case sealing process 2000) The flowchart shown describes the operation of the case sealing machine 10 to seal the case C. In this exemplary embodiment, the operator is a human.

[0066] Initially, as Figure 9A As shown, the top head assembly 400 is in its initial (lower) position, the side rails 114a and 114b are in their rest configuration, and the box lifter 210 is in the box lift position. The controller 90 controls the lower drive assembly actuator 118 and the upper drive assembly actuator 422 to respectively drive the first lower drive element 115a and the second lower drive element 115b of the base assembly 100 and the upper drive element of the top head assembly 400, as indicated by block 2002.

[0067] The operator places a box C on the infeed table 112. The infeed table sensor S1 detects the presence of the box C, as indicated by block 2004, and in response sends a corresponding box detected signal to the controller 90. In response to receiving the box detected signal, the controller 90 controls the side rail actuators 117 to move the side rails 114a and 114b from the idle configuration to the centered configuration, such that the side rails 114a and 114b move laterally inward to engage and center the box C on the infeed table 112, as indicated by block 2006.

[0068] Then, the operator moves the box C into contact with the front surface sensor S2, as shown in FIG. Figure 9BThis causes the front surface sensor S2 to detect the box C (via the box C contacting and actuating the paddle switch of the front surface sensor S2), as indicated by block 2008, and in response, sends a corresponding box-detected signal to the controller 90. In response to receiving the box-detected signal, the controller 90 controls the top head actuation assembly 305 (and more specifically, the top head actuation assembly actuator(s) 310) to cause the top head assembly 400 to begin raising, as indicated by block 2010.

[0069] As the top head assembly 300 moves upward, the front surface sensor S2 eventually stops detecting the box C, as indicated by block 2012 and as Figure 9C This indicates that the top head assembly 400 has risen above the top surface of the box C. In response to no longer detecting the box C, the front surface sensor S2 sends a corresponding box-not-detected signal to the controller 90. In response to receiving this signal, the controller 90 controls the top head actuation assembly 305 (and more specifically, the top head actuation assembly actuator(s) 310) to enable the top head assembly 400 to stop its ascent and begin descending, as indicated by block 2014.

[0070] Once the top head assembly 400 is raised above the top surface of the box C, the operator moves the box C below the top head assembly 300. As the operator does so, the box C engages the box engagement surface 211a of the body 211 of the box lifter 210 and moves along that surface toward the box stopper 215 of the box lifter 210. Because the box engagement surface 211a is inclined relative to the first and second lower drive elements 115a, 115b, it forms a ramp that lifts the lower surface of the box C above and out of contact with the first and second lower drive elements 115a, 115b. The box C eventually engages the box engagement surface 215a of the box stopper 215, reaching a holding position, at which point the operator stops moving the box C because the box stopper 215 prevents further movement of the box in the D direction. Figure 9C Box C is shown in a holding position.

[0071] As the box C moves beneath the top head assembly 400 and toward the holding position, the box entry sensor S3 detects the presence of the box C beneath the top head assembly and, in response, sends a corresponding box detected signal to the controller 90, as indicated by block 2016. In response to receiving the box detected signal, the controller 90 begins monitoring for a box detected signal from the box lifter sensor S4 as the top head assembly 400 continues to descend. Eventually, the box lifter sensor S4 detects the presence of the box C and, in response, sends a box detected signal to the controller 90, as indicated by block 2018. In response to receiving the box detected signal, the controller 90 controls the box lifter actuator 240 to move the box lifter 210 from its box lifting position to its retracted position, as indicated by block 2020. When this occurs, the box C is lowered onto the first lower drive element 115a and the second lower drive element 115b, as shown in FIG. Figure 9D As shown, the two drive elements begin to move box C in direction D. Shortly thereafter (or simultaneously with or shortly before, depending on the embodiment), the upper drive element of the upper drive assembly of the top head assembly 400 engages the top surface of the box and couples the first and second lower drive elements during movement of box C in direction D.

[0072] The controller 90 receives a signal from the arm retraction sensor S5 indicating that a box C has been detected (indicating that the arm retraction sensor S5 has detected box C), and in response, controls the roller arm actuator 1710 and the cutter arm actuator 1810 to move the first and second roller arms 1110, 1120, and the cutter arm 1301 to their respective retracted positions, as indicated by block 2024. When the front roller arm 1110 moves to its retracted position, the front surface of box C contacts the front roller 1120 of the tape cassette 1000, thereby causing the tape positioned on the front roller 1120 to adhere to the front surface of box C. When the front roller arm 1110 and the rear roller arm 1210 are in their retracted positions, the front roller 1120 and the rear roller 1220 are positioned so that they apply sufficient pressure to the tape to cause the tape to adhere to the top surface of box C. When the cutter arm 1301 is in its retracted position, the cutter arm 1301 does not contact the top surface of box C (although it may do so in some embodiments). The controller 90 controls the roller arm actuator 1710 and the cutter arm actuator 1810 to maintain the front and rear roller arms 1110, 1210, and the cutter arm 1301 in their respective retracted positions as the top drive assembly 320 and the lower drive assembly 115 move the box C past the tape cassettes 1000a and 1000b.

[0073] Box C eventually moves off the infeed station 112, at which point the infeed station sensor S1 ceases to detect box C and sends a corresponding box-not-detected signal to the controller 90. In response to receiving the box-not-detected signal, the controller 90 controls the side rail actuators 117 to move the side rails 114a and 114b from the centered configuration to the idle configuration, thereby making room on the infeed station 112 for the next box to be sealed.

[0074] At some point, the box exit sensor S6 detects the presence of box C, as indicated by block 2026 (but this may occur after the retract sensor S5 stops detecting box C, depending on the length of the box) and sends a corresponding box detected signal to the controller 90.

[0075] Once the box C moves past the box lifter 210, the box lifter sensor S4 ceases to detect the box C and sends a corresponding box-not-detected signal to the controller 90, as indicated by block 2028. In response to receiving the box-not-detected signal, the controller 90 controls the box lifter actuator 240 to move the box lifter 210 from its retracted position to its box-lifting position in preparation for the next box to be sealed.

[0076] Once the arm retraction sensor S5 ceases to detect the box (indicating that the box has moved past the arm retraction sensor S5), the arm retraction sensor S5 sends a corresponding non-box detection signal to the controller 90, as indicated by block 2032. In response, the controller 90 controls the roller arm actuator 1710 to return the first roller arm 1110 and the second roller arm 1120 to their respective extended positions, thereby applying the tape to the rear surface of the box, and controls the cutter arm actuator 1810 to return the cutter arm 1301 to its extended position, thereby cutting the tape from the roll, as indicated by blocks 2034 and 2036. As this occurs, the fingers 1344 of the cutting device cover 1340 contact the top surface of the box, causing the cutting device cover 1340 to pivot to the open position and expose the cutting device 1330. The cutter arm 1301 continues to move, causing the toothed blade of the cutting device 1330 to contact the tape and sever the tape from the roll R. As the front roller arm 1110 and the rear roller arm 1210 move back to their extended positions, the rear roller arm 1210 moves so that the rear roller 1220 contacts the severed end of the tape and applies the tape to the rear surface of the box C to complete the taping process.

[0077] The upper drive assembly 420 and the lower drive assembly 115 continue to move the box C until the box exits from under the top head assembly 400 and is placed on the delivery platform 113. At this point, the box exit sensor S6 stops detecting the box, as indicated by block 2038, and sends a corresponding box-undetected signal to the controller 90. The top head assembly 400 then descends back to its initial position, as indicated by block 2040.

[0078] The box lifter solves this problem. The box lifter acts as a ramp (when in the box lift position) to raise the box above the lower drive element when it reaches the holding position. This eliminates the need for the operator to hold the box in place against the constant pull of the lower drive element while waiting for the top head assembly to descend. Furthermore, the inclusion of a box stopper on the box lifter ensures that the box will remain in the holding position and will not move too far below the top head assembly until the top head assembly has descended to within a specified distance of the top surface of the box.

[0079] In some embodiments, the tape cassette includes biasing elements that bias the roller arm and the cutter arm to their respective extended positions. The biasing elements eliminate the need to directly actuate the roller arm and the cutter arm from their respective retracted positions to their respective extended positions.

[0080] In some embodiments, the controller is separate from the sensors and supplements the sensors. In other embodiments, the sensors act as their own controllers. For example, in one embodiment, the retraction sensor is configured to directly control the cutter and roller arm actuators in response to detecting the presence and absence of a box, the feed station sensor is configured to directly control the side rail actuators in response to detecting the presence and absence of a box, and the front surface sensor and top surface sensor are configured to directly control the top head actuator in response to detecting the presence and absence of (or contact with) a box.

[0081] In certain embodiments, the box lifter does not include a box stopper.

[0082] In some embodiments, the box stopper is not an element extending from the box engaging surface of the box lifter, but rather comprises a recess defined in the box engaging surface of the box lifter. In these embodiments, the recess is sized and shaped to "catch" the bottom corner of the front surface of the box as it moves along the box engaging surface and reaches the retaining position.

[0083] In other embodiments, when the case entry sensor detects the presence of a case below the top head assembly and, in response, sends a corresponding case detection signal to the controller, the controller stops driving the lower drive element (and, in some embodiments, stops driving the upper drive element). Thereafter, when the case lifter sensor detects a case and, in response, sends a corresponding case detection signal to the controller, the controller starts driving the lower drive element (and, in some embodiments, starts driving the upper drive element). Stopping the drive element provides a backup plan to prevent the case from being pushed too far below the top head assembly in the event that the case moves below the top head assembly or moves prematurely to a retracted position without the case lifter in its blocking position. In some of these embodiments, the case sealer does not include a case lifter assembly, and the case lifter sensor is a drive stop sensor.

Claims

1. A carton sealing machine, comprising: frame; lower drive element; a lower drive element actuator operatively connected to the lower drive element and configured to drive the lower drive element; as well as a box lifter movable relative to the lower drive element between a box lifting position in which a portion of the box lifter is above a top surface of the lower drive element and a retracted position in which the portion of the box lifter is not above the top surface of the lower drive element, wherein, when the box lifter is in the box lifting position, the portion of the box lifter is oriented to lift a portion of the box above and out of contact with the lower drive element as the box moves onto the box lifter.

2. The carton sealing machine according to claim 1, wherein: The box lifter is pivotable relative to the lower drive element between the box lifting position and the retracted position.

3. The carton sealing machine according to claim 2, wherein: The frame at least partially defines an infeed end and an outfeed end of the case sealer, wherein the case lifter pivots away from the infeed end and toward the outfeed end when pivoting from the case lifting position to the retracted position.

4. The carton sealing machine according to claim 1, wherein: The portion of the box lifter forms a ramp when the box lifter is in the box lifting position.

5. The case sealer of claim 1 , further comprising a box lift actuator operably connected to the box lift and configured to move the box lift.

6. The carton sealing machine according to claim 5, wherein: The box lift actuator is configured to move the box lift from the retracted position to the box lift position.

7. The carton sealing machine according to claim 5, further comprising: Top head assembly; a top head assembly actuator operatively connected to the top head assembly to move the top head assembly relative to the frame; a box lifter sensor configured to detect a box beneath the top header assembly and configured to transmit a box detected signal in response to detecting the box; as well as a controller communicatively connected to the box lifter sensor and operatively connected to the box lifter actuator, the controller configured to control the box lifter actuator to move the box lifter from the box lift position to the retracted position in response to receiving the box detected signal from the box lifter sensor.

8. The carton sealing machine according to claim 7, wherein: The box lifter sensor is further configured to transmit a box not detected signal in response to no longer detecting the box, wherein the controller is further configured to move the box lifter from the retracted position to the box lifted position in response to receiving the box not detected signal from the box lifter sensor after receiving the box detected signal from the box lifter sensor.

9. The case sealer of claim 8, further comprising a biasing element for biasing the case lifter to the case lifting position.

10. The carton sealing machine according to claim 8, wherein: The box lift actuator is operatively connected to the box lift to move the box lift from the retracted position to the box lift position, wherein the box lifter sensor is configured to send a box not detected signal to the controller in response to the box no longer being detected, The controller is further configured to control the box lift actuator to move the box lift from the retracted position to the box lifting position in response to receiving the box non-detected signal from the box lift sensor.

11. The carton sealing machine according to claim 7, wherein: The box lifter sensor is configured to detect the box within a specified distance of the top head assembly.

12. The carton sealing machine according to claim 1, wherein: The lower drive element includes a first lower drive element and further includes a second lower drive element spaced apart from the first lower drive element, wherein the box lifter forms a ramp between the first lower drive element and the second lower drive element when in the box lift position.

13. The carton sealing machine according to claim 1, wherein: The portion of the box lifter includes a box engaging surface, wherein the box lifter further includes a box stopper positioned above a top surface of the lower drive element when the box lifter is in the box lifting position and not above the top surface of the lower drive element when the box lifter is in the retracted position.

14. The carton sealing machine according to claim 13, wherein: The box stopper extends from a box engaging surface of the box lifter.

15. The carton sealing machine according to claim 13, further comprising: Top head assembly; a top head assembly actuator operatively connected to the top head assembly to move the top head assembly relative to the frame; a box lift actuator operatively connected to the box lift and configured to move the box lift; a box lifter sensor configured to detect a box beneath the top header assembly and configured to transmit a box detected signal in response to detecting the box; as well as a controller communicatively connected to the box lifter sensor and operatively connected to the box lifter actuator, the controller configured to control the box lifter actuator to move the box lifter from the box lift position to the retracted position in response to receiving the box detected signal from the box lifter sensor.

16. A method for operating a case sealing machine to apply tape to a case, the method comprising: driving the lower driving element of the carton sealing machine; detecting the box near a top head assembly of the box sealing machine; in response to detecting the box proximate the top head assembly, raising the top head assembly above a top surface of the box; automatically moving the case lifter to lower the case portion into contact with the lower drive element once the case is within a specified distance of the top head assembly after the case portion has moved onto a case lifter positioned below the top head assembly and holding the case portion above and out of contact with the lower drive element; engaging the box with the top header assembly; as well as The box is moved via the lower drive element past a tape cassette of the case sealer to apply tape to the box.

17. The method of claim 16, further comprising: The box is detected within a specified distance of the top header assembly and, in response, the box lifter is automatically moved to lower the box by controlling an actuator to move the box lifter from a box lifting position to a retracted position.

18. The method of claim 17, further comprising: As the top head assembly is lowered toward the box, the box is detected to be within a specified distance of the top head assembly.

19. The method of claim 17, further comprising: The box is engaged with the top header assembly while or after the box lifter is moved to lower the box.

20. The method of claim 16, wherein: Moving the box past the tape cassette further includes moving the box past the tape cassette via an upper drive element of the top head assembly.

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