Autonomous mobile robot vehicle-mounted production line end box processing

Abstract

A packaging system for production line end box handling includes two or more production line end box handling stations, each configured to perform one or more production line end handling operations, an autonomous vehicle, and a controller. The box handling station includes a box supply, a product delivery station that places an object to be transported in the box, and a sensor for detecting characteristics of the box and the object in the box. The autonomous vehicle is configured to autonomously transport boxes from the product delivery station to selected ones of the two or more box handling stations. The controller is in communication with the sensor and the autonomous vehicle and is configured to selectively direct the autonomous vehicle to transport the box from the product delivery station to another selected one of the two or more box processing stations based at least in part on information from the sensor.

Description

Technical Field

[0001] The present invention generally relates to a packaging system for handling boxes at the end of a production line, and more particularly, to a packaging system for handling boxes at the end of a production line using an autonomous mobile robot. Background Art

[0002] In the process of transporting one or more objects from one location to another, before the package is ready to be transported, the package may undergo multiple end-of-production-line handling operations. Some exemplary end-of-production-line handling includes forming or erecting a box, loading the object to be transported and optional protective packaging materials into the box, and closing, covering, or sealing the box. Whether such end-of-production-line handling is performed manually or by an automatic or semi-automatic packaging system, the box is typically conveyed from the upstream end of a fixed, permanent conveyor system (such as a continuous conveyor system), and the conveyor system defines a fixed path for each package as the box moves downstream through each of a plurality of stations performing the various end-of-production-line handling operations. Summary of the Invention

[0003] The present disclosure describes a packaging system for performing end-of-production-line box handling on an autonomous vehicle, such as an autonomous mobile robot that replaces a fixed transport system (e.g., a conveyor). Using an autonomous transport device and a control system that conveys packaging containers only to selected packaging stations provides several advantages, including greater flexibility for workers to move around and within the packaging system, and greater flexibility in placing packaging stations within the packaging area, making reconfiguration easier and reducing the need for human decision-making between stations. The absence of a fixed path can also accelerate the packaging process by delivering containers only to the packaging stations where they are needed and bypassing packaging stations where no packaging operations are required, thereby freeing up space at these packaging stations for containers that require these packaging operations and avoiding delays for containers that do not require these packaging operations due to waiting for the preceding containers to pass through the packaging stations.

[0004] An exemplary packaging system for end-of-line case handling includes two or more end-of-line case handling stations, an autonomous vehicle, and a controller. Each end-of-line case handling station is configured to perform one or more end-of-line case handling operations. The end-of-line case handling station includes a source of cases, a product delivery station for placing an object to be transported in a case, and a sensor for detecting characteristics of the case and the object in the case. The autonomous vehicle is configured to autonomously transport a case from the product delivery station to a selected one of the two or more end-of-line case handling stations. And the controller is operably communicable with the sensor and the autonomous vehicle. The controller is configured to selectively direct the autonomous vehicle to autonomously transport the case from the product delivery station to other selected ones of the two or more end-of-line case handling stations, at least in part based on information from the sensor.

[0005] According to one or more embodiments of the packaging system, the autonomous vehicle is an autonomous mobile robot, and the case is located on the autonomous mobile robot when at least one of the one or more end-of-line case handling operations is performed on the case.

[0006] In one or more embodiments, the sensor is configured to detect at least one characteristic of the case, the characteristic including at least one of a height dimension, a width dimension, a depth dimension, and a void volume. At least one detected characteristic may include an indicator of non-conformance of the case.

[0007] In one or more embodiments, the controller is configured to direct the autonomous vehicle to autonomously transport the case along a route that bypasses at least one of the two or more end-of-line case handling stations.

[0008] In one or more embodiments, at least one of the two or more end-of-line case handling stations is automated.

[0009] In one or more embodiments, at least one of the two or more end-of-line case handling stations includes a first end-of-line case handling station and a second end-of-line case handling station disposed remote from the first end-of-line case handling station such that the autonomous vehicle can be directed to a selected one of the first end-of-line case handling station and the second end-of-line case handling station rather than the other of the first end-of-line case handling station and the second end-of-line case handling station. The first end-of-line case handling station and the second end-of-line case handling station may perform the same end-of-line case handling operation, or the first end-of-line case handling station and the second end-of-line case handling station may perform different end-of-line case handling operations.

[0010] An exemplary end-of-line box handling method includes the following steps: (a) providing a packaging system having two or more end-of-line box handling stations and one or more autonomous carriers configured to move boxes between selected ones of the two or more end-of-line box handling stations, the end-of-line box handling stations including a product delivery station at which an object to be transported is placed in a box for transportation; (b) loading the box onto an autonomous carrier to transport the box to a selected one of the two or more end-of-line box handling stations; (c) scanning the box to detect characteristics of the box and the object in the box after the object to be transported is placed in the box; and (d) guiding the autonomous carrier to transport the box along a route from the product delivery station to a selected one of the two or more end-of-line box handling stations based at least in part on the detected characteristic information.

[0011] According to one or more embodiments of the end-of-line box handling method, the method further includes the step of selectively causing at least one of the one or more end-of-line box handling stations to perform at least one of one or more end-of-line box handling operations on the box. When performing at least one of the one or more end-of-line box handling operations on the box, the box may be located on the autonomous carrier.

[0012] In one or more embodiments, the method further includes the step of detecting at least one characteristic of the box and updating the route based at least in part on the detected characteristic. The detecting step may include identifying at least one detected characteristic that indicates the box is non-conforming.

[0013] In one or more embodiments, the guiding step includes instructions for bypassing at least one end-of-line box handling station.

[0014] In one or more embodiments, the loading step includes erecting the box and placing the box on the autonomous carrier.

[0015] In one or more embodiments, the scanning step includes detecting one or more of the following: the height dimension of the box, the width dimension of the box, the depth dimension of the box, the height dimension of one or more objects in the box, non-conforming characteristics of the box, and the void volume of the box. The scanning step may be repeated after the box is transported to at least one end-of-line box handling station.

[0016] In one or more embodiments, the method may further include the step of transporting the box to multiple end-of-line box handling stations. Description of the Drawings

[0017] Figure 1is a schematic layout of an exemplary packaging system for case handling at the end of a production line;

[0018] Figure 2 is a schematic operational view of an exemplary case handling operation at the end of a production line, showing an autonomous mobile robot moving autonomously towards a case handling station at the end of the production line;

[0019] Figure 3 is Figure 2 a schematic operational view of an exemplary case handling operation at the end of a production line, showing an autonomous mobile robot interacting with a case handling station at the end of the production line to receive a lid on a case on the autonomous mobile robot; and

[0020] Figure 4 is a schematic flow chart of an exemplary case handling method at the end of a production line. Detailed Description

[0021] Turning now to the drawings, first to Figure 1 , which shows a schematic view of an exemplary automated packaging system 10 for case handling at the end of a production line. The packaging system 10 includes a plurality of case handling stations at the end of the production line and one or more autonomous carriers 12 for moving packaging containers 14 through selected ones of the case handling stations at the end of the production line. The case handling stations at the end of the production line are arranged such that the autonomous carriers 12 have maneuvering space to bypass any of the case handling stations at the end of the production line. By using the autonomous carriers 12, the packaging system 10 minimizes or eliminates the need for a permanently continuous conveyor system in a fixed location (such as that used in traditional packaging systems for case handling at the end of a production line). Using the autonomous carriers 12 and a control system for only delivering the packaging containers to selected case handling stations at the end of the production line provides several advantages, including greater flexibility for workers to move within the packaging system 10 and greater flexibility in placing the case handling stations at the end of the production line within the packaging area, making reconfiguration easier.

[0022] The need for a fixed path can also be eliminated to speed up the packaging process by simply delivering the containers to the desired end-of-line case handling stations and bypassing the end-of-line case handling stations that do not require the packaging operation, thereby freeing up the space of these end-of-line case handling stations for the containers that require these end-of-line handling operations and avoiding delays caused by containers that do not require these end-of-line handling operations having to wait for the previous containers to pass through the end-of-line case handling stations. For example, the packaging system 10 described herein provides independent modular end-of-line case handling stations that can be arranged in any desired configuration, and the system controller 40 instructs the autonomous vehicle 12 to move the transport container 14 through the selected stations among the multiple end-of-line case handling stations when the packaging container 14 is located on the autonomous vehicle 12, rather than arranging the multiple end-of-line case handling stations at fixed positions along a permanent conveyor system and conveying the packaging containers downstream from one end of the permanent conveyor system through each end-of-line case handling station. The modular nature of the end-of-line case handling stations also facilitates maintenance and improves scalability, implementability, and process variation.

[0023] Throughout the specification, the terms "container" and "case" are interchangeable and refer to any enclosure of sufficient strength to withstand transportation, storage, and handling, and the required characteristics typically vary according to the nature of the object to be transported within the enclosure. The most common shipping containers are cardboard boxes, such as a conventional slotted container (RSC) with flaps and a half-slotted container (HSC, also known as a shoebox container). The flaps are folded down to close the open side of the container. A separate lid is typically secured to the half-slotted container with an adhesive to close the open side of the container. Cardboard containers can also have different types and different structural forms. However, the term "case" is not limited to cardboard boxes or any other material.

[0024] The end-of-line case handling station includes more than one case delivery station 20 (sometimes referred to as a case forming station or a case erecting station) for providing cases 14 to the autonomous vehicle 12; a product delivery station 22 (sometimes referred to as a product filling station or a case loading station) for providing an object 52 to be shipped in the case 14; a scanning station 24 for detecting characteristics of the case 14 and the object in the case 14; a case sizing station 26 for reducing the height dimension of the case 14 based on the detected characteristics of the object 25 in the case 14; a padding dispensing station 30 for providing padding material to the case 14; a capping station 34 for folding inwards the flaps of the case 14 on the open side of the case 14 and for applying a lid on the open side of the case 14; and a label applying station 36 for applying a shipping label on the case 14. Each end-of-line case handling station can be designed as an independent modular end-of-line case handling station which can be positioned or moved to any suitable location within the end-of-line case handling area. Each end-of-line case handling station is spaced apart from other end-of-line case handling stations to facilitate movement between the end-of-line case handling stations.

[0025] In addition, while some of these end-of-line case handling stations can be combined to provide all functions in one rather than two or more end-of-line case handling stations, or some of these end-of-line case handling stations can be divided into multiple end-of-line case handling stations, the packaging system 10 has the advantage over prior fixed conveyor systems of being able to route cases around an end-of-line case handling station without waiting for the preceding case to leave the end-of-line case handling station. For example, if shipping labels are always added to the case 14 after the open side of the case 14 is closed at the capping station 34, the label applying station 36 can be combined with the capping station 34. However, combining the case sizing station 26 and the padding dispensing station 30 would prevent the case 14 from routing around the case sizing station 26 to reach the padding dispensing station 30, which would slow down the end-of-line processing, especially when not every case 14 requires the processing operation of the case sizing station 26.

[0026] As another example, if the packaging system 10 processes cases 14 with and without flaps, the capping station 34 can be divided into two different types, one being a capping station 34 for cases 14 with flaps which has flap folding and capping capabilities, and one being a capping station 34 for cases 14 without flaps which does not have flap folding capabilities (or the flap folding feature is disabled) but has capping capabilities. In fact, cases 14 without flaps can route around the flap folding station.

[0027] Although in combination with Figure 1The embodiments describe a particular end-of-line case handling station, but the end-of-line case handling station can be any suitable end-of-line case handling station and, as a further example, can include a padding transfer station, a scanning system, a printing station, a label application station, a height reduction station, a non-conformance detection station, a non-conformance correction station, other quality assurance stations, and a protective packaging system and its associated consumables. This list is not exhaustive.

[0028] The packaging system 10 also includes a system controller 40 for controlling the cooperation and interaction between the various components of the packaging system 10 and the end-of-line case handling stations 20, 22, 24, 26, 30, 34, and 36. However, one or more components of the packaging system 10 and the end-of-line case handling stations can be controlled manually or independently of each other, semi-automatically or automatically. The system controller 40 can be a programmable controller that is appropriately programmed to operate the packaging system 10 in a desired manner for a given application. The operation of the system controller 40 can be performed by a single processor device or separate processor devices for the various components of the packaging system 10, which are appropriately connected to coordinate the operation of the packaging system 10 as a whole.

[0029] For example, the system controller 40 can perform operations in response to executing software instructions stored on a non-transitory computer-readable medium, such as a non-transitory storage device that includes storage space within a single physical storage device or storage space distributed across multiple physical storage devices. The software instructions can be stored locally within the system controller 40 or can be received remotely via a communication interface from another non-transitory computer-readable medium (e.g., the non-transitory computer-readable medium of a computing device arranged remotely from the system controller 40 and operably communicable with the system controller 40 via a wireless protocol).

[0030] When executed, the software instructions stored in the memory or other storage components associated with the system controller 40 can cause the system controller 40 to perform one or more of the operations described herein. Additionally, or alternatively, hardwired circuitry can be used in place of or in combination with the software instructions to perform one or more of the processes described herein. Accordingly, the embodiments described herein are not limited to any particular combination of hardware circuitry and software.

[0031] Accordingly, system controller 40 may include a central processing unit (CPU), a graphics processing unit (GPU), an accelerated processing unit (APU), a microprocessor, a microcontroller, a digital signal processor (DSP), a field programmable gate array (FPGA), an application specific integrated circuit (ASIC), any other suitable type of processor, or a combination thereof. The processor may be implemented in hardware, software, or a combination of hardware and software. In some embodiments, system controller 40 may include a memory, such as random access memory (RAM), read only memory (ROM), another type of dynamic or static storage device (e.g., flash memory, magnetic memory, optical memory, etc.), or a combination thereof, that stores information or instructions used by system controller 40.

[0032] The components of packaging system 10 may be operably communicable with each other directly or via system controller 40 over a communication network 42 (e.g., a wireless communication network). However, the components of packaging system 10 may be operably communicable via any suitable combination of one or more wired, wireless, or combined networks. For example, communication network 42 may include any one or more of the Internet, an intranet, a cloud network, a wide area network (WAN), a local area network (LAN), a wireless network, a digital subscriber line (DSL) network, a frame relay network, an asynchronous transfer mode (ATM) network, a virtual private network (VPN), any other suitable communication network, or a combination of communication networks.

[0033] Figure 1 At least one autonomous vehicle 12 may include an autonomous mobile robot (AMR) 12 for autonomously transporting bins 14 through packaging system 10. Each AMR 12 includes an on-vehicle navigation system for navigating through packaging system 10 without a predefined fixed physical path. The on-vehicle navigation system may include an inertial navigation system (INS) 44 (see Figure 2 ) and a navigation system 46 (see Figure 2)。The INS 44 and the navigation system 46 may include computing devices, motion sensors, rotation sensors, Global Positioning System (GPS), or any other suitable components or combinations thereof. The INS 44 allows the system controller 40 to determine the position, orientation, and velocity of the AMR 12 without relying on external references, and the navigation system 46 allows the system controller 40 to independently and selectively control each AMR 12 when the AMR 12 moves along a desired route, as further described below. For example, the INS 44 may calculate the position, orientation, and velocity by dead reckoning and transmit the position data, orientation data, and velocity data to the system controller 40. However, the AMR 12 may use any other suitable positioning system, such as external positioning markers or signals at the end-of-line processing stations of the production line.

[0034] Generally, each AMR 12 moves independently of the system controller 22 along a selected route between the end-of-line processing stations of the production line. In other words, the system controller 22 may indicate which end-of-line case processing station the AMR 12 should visit without predefining the route that the AMR 12 must take between two end-of-line case processing stations. In other words, for example, without indicating in real time when the AMR 12 should turn. This also means that, if needed, the system controller 40 may instruct the AMR 12 to visit the end-of-line case processing station multiple times, or instruct the AMR 12 to navigate between a group of end-of-line case processing stations, which is only used in very rare cases and is economically infeasible for a fixed-route transportation system. Therefore, Figure 1 the AMR 12 routes shown in are merely several possible routes that the AMR 12 may take, and the AMR 12 is not limited to the paths shown.

[0035] The packaging system 10 preferably includes a plurality of AMR 12s to automatically and substantially independently move a plurality of cases 14 through the end-of-line processing stations without continuous control by the system controller 40. The AMR 12s may be part of the supply of AMR 12s at the upstream end of the end-of-line processing stations, or the AMR 12s may queue at the end-of-line processing stations until needed.

[0036] In the illustrated embodiment, the first end-of-line processing station is the case delivery station 20, which includes one or more supplied cases 14. The case 14 may be formed of flat cardboard that is cut, folded, and glued to form a top-open case 14, or the case may be supplied as a pre-folded flat case 14, and the case 14 is opened and its bottom side is closed at the case delivery station 20. Machines for opening flat-folded cases are generally referred to as case erectors.

[0037] The illustrated container delivery station 20 includes a plurality of container erectors 50 to accelerate the conveyance of containers 14 or to provide different cross-sectional dimensions (width and depth) and heights for the containers 14. For example, the container delivery station 20 may include two container erectors 50 for erecting containers 14 having a smaller cross-sectional dimension, one of the two container erectors 50 erecting a container 14 having a lower height and the other of the two container erectors 50 erecting a container 14 having a higher height. The container delivery station 20 may further include more than two container erectors 50 for erecting containers 14 having a larger cross-sectional dimension, wherein one of the two container erectors 50 erects a container 14 having a lower height and the other of the two container erectors 50 erects a container 14 having a higher height. Thus, this embodiment will provide four different sizes of containers 14 having four different combinations of height, width, or depth dimensions.

[0038] For example, a packer or other operator at the product delivery station 22 may communicate via the communication network 42 to send a signal to the container delivery station 22 requesting a container 14. If the container delivery station 22 provides a variety of different container sizes or types, the signal will include the size or type of the desired container 14, and the AMR 12 will navigate to the appropriate location to receive the desired container. Optionally, the AMR 12 may be located at each of a plurality of locations within the container delivery station 22 to be ready to receive a container 14 of a particular size or type at each such location.

[0039] The container delivery station 22 places the container 14 on the AMR 12 such that the AMR 12 supports the container 14 and moves with it. The AMR 12 then travels from the container delivery station 22 to the product delivery station 24 where one or more objects 52 are placed in the container for shipment. The product delivery station 24 may automatically perform a product filling operation, for example, using a robot to pick up the object 52 to be transported from its supply and place the object 52 inside the container 14 on the AMR 12. Alternatively, the packer may manually place the object 52 to be transported into the container 14. The object 52 to be transported may include a plurality of items. When the object 52 is placed in the container 14, the container 14 either remains on the AMR 12 or the container 14 is moved to the product delivery station 22 for filling and then returns to the AMR 12 after the object 52 is placed in the container 14.

[0040] The container 14 is tracked through the remaining selected end-of-line container handling stations (e.g., from the identification of the AMR 12 transporting the container 14 or through the identification of the container 14 itself, such as through sensors at or around the end-of-line handling station). The sensors can include sensors capable of detecting, for example, barcodes or radio frequency identification devices (RFID) disposed on the container 14 or the AMR 12.

[0041] From the product delivery station 24, the AMR 12 moves the container 14 through the quality scan station 24, where sensors communicating with the system controller 22 determine the container dimensions, void volume, and the height of the tallest item in the container 14 and transmit this information to the system controller 40. In other words, the sensors can be configured to identify: characteristics of the container 14, the contents of the container 14, or a combination thereof; eligibility criteria for the container 14, the contents of the container 14, or a combination thereof; and the dimensions of the space of the container 14 relative to the contents of the container 14.

[0042] The system controller 40 determines, at least in part based on the information from the sensors at the quality scan station 24, the end-of-line handling operations required for the container 14 and its contents and instructs the AMR 12 to move the container 14 through the selected stations among the remaining end-of-line handling stations in a particular order or simply instructs the AMR 12 to move the container 14 to the next selected station among the end-of-line handling stations.

[0043] In the illustrated embodiment, the next end-of-line handling station can be the container sizing station 26, where the container dimensions (particularly the height dimension) can be reduced as a function of the tallest object in the container 14. The exemplary container sizing station 26 cuts the corners of the container 14 to a height close to the tallest object in the container 14 and forms a fold line in the container 14 at a height close to the tallest object in the container 14. If no sizing adjustment is needed, the AMR 12 can bypass the container sizing station 26 and any AMR in the container sizing station 26, thereby changing the order of the containers 14 being processed at the end-of-line handling stations.

[0044] Another end-of-line processing station is the dunnage distribution station 30. The dunnage distribution station 30 includes one or more protective packaging machines having dunnage dispensers configured to dispense dunnage products into the enclosure 14. The AMR 12 can be directed along a path to a particular dunnage dispenser, or if dunnage is not required, the AMR 12 can bypass the dunnage distribution station 30 and any AMR 12 within the dunnage distribution station 30. Each dunnage dispenser dispenses protective packaging material (also referred to as dunnage, dunnage pad, or dunnage product) into the enclosure 14 to protect the object 52 within the enclosure 14 during transportation. Some exemplary protective packaging machines include void fill systems, cushioning systems, and wrapping systems.

[0045] A void fill system can quickly and efficiently convert inventory material (e.g., paper) into fill material to fill voids within the enclosure 14 and protect the object 52 therein by reducing movement of the object 52 during transportation and potential damage suffered during transportation. A cushioning system typically converts inventory material such as paper into a cushioning pad by folding and crumpling the paper to form a shock-absorbing material so that the object 52 is protected from external shocks and vibrations during transportation and the object 52 is prevented from moving during transportation. For example, a wrapping system can produce relatively flat pads or nets to firmly package and protect the object 52 from shocks and surface damage during transportation and handling, and can also be used to line the enclosure 14 and provide separation when transporting multiple products. A thermal insulation system provides thermal insulation for objects 52 that require temperature control during transportation.

[0046] The packaging system 10 can include multiple dunnage dispensers 54 within the dunnage distribution station 30, each dunnage dispenser 54 configured to convey the same or different types or qualities of dunnage (e.g., void fill, cushioning, wrapping, or insulating materials, which are converted from different inventory materials), or configured to provide redundancy to accommodate larger volumes of dunnage dispensing (e.g., by dispensing dunnage into multiple enclosures at different dunnage dispensers 54, or using papers of different basis weights for different dunnage dispensers 54). If multiple types of dunnage are required, the AMR 12 can be directed to the dunnage distribution station 30 multiple times. For example, a flat wrapping pad or insulating pad can be placed in the enclosure 14 before any object 52 to be transported is placed in the enclosure 14, and then the object 52 to be transported is placed on top of the previously inserted dunnage pad. Thus, the AMR 12 can be directed to the dunnage distribution station 30 before and after the product delivery station 22, as appropriate.

[0047] Once the bin 14 is ready to be closed, the AMR 12 automatically moves the bin 14 to the capping station 34. As part of the bin capping operation, the capping station 34 can include folding arms to fold the upright flaps inwardly over the open top side of the bin 14, thereby partially or fully closing the open top side of the bin 14. If the flaps do not fully close the open side of the bin 14, the capping station 34 can place a lid on the bin 14 to close the open side of the bin 14, as Figure 3 shown, where the capping station 34 is shown placing the lid 56 on the bin 14 while the bin 14 is supported on the AMR 12. If the bin 14 does not have flaps that need to be folded prior to applying the lid, an alternative capping station 34 can be provided for flapless bins 14.

[0048] After the lid 56 has been placed on the bin 14, the AMR 12 can move the bin 14 to the label application station 36 where a shipping label 60 can be applied to the bin 14. In addition to or as an alternative to simply applying the shipping label 60 to the bin 14, the label application station 36 can provide the shipping label 60 by printing directly onto the bin 14 or printing the shipping label onto a sticky label after the sticky label has been attached to the bin 14. Once the end-of-line processing is complete, the bin 14 is removed from the AMR 12. The AMR 12 is then sent back to the AMR supply until needed or is directed directly to the bin supply station 20 to receive another bin 14.

[0049] The packaging system 10 can include additional sensors adjacent to one or more of the end-of-line processing stations to inspect for non-conforming bins. For example, when the AMR 12 moves away from the padding dispensing station 30, the sensors can inspect for non-conformities such as incorrectly bent flaps, protruding sidewalls, or the bin 14 has moved out of position relative to the AMR 12, i.e., the sidewalls of the bin 14 are no longer parallel to the sidewalls of the AMR 12. After determining that the bin 14 is non-conforming, the system controller 40 can send an updated route planning signal (not shown) to the AMR 12 that changes the previously determined route of the AMR 12 such that the AMR 12 moves the bin to an end-of-line processing station to remedy the non-conformity. The non-conforming bin 14 can be made conforming in any suitable manner, such as through an automated compliance station (not shown) or manually by an operator.

[0050] Reference will now be made to Figure 5Describe an exemplary end-of-line case handling method 300 that uses the above-described packaging system 10. The method includes step 302: providing the packaging system 10, which has two or more end-of-line case handling stations and one or more autonomous carriers 12 configured to move cases 14 between selected ones of the two or more end-of-line case handling stations. The end-of-line case handling stations include a product delivery station 22 at which an object 52 to be transported is placed in the case 14 for transportation. The method further includes step 304: loading the case 14 onto the autonomous carrier 12 to transport the case 14 to a selected one of the two or more end-of-line case handling stations. After the object 52 to be transported is placed in the case 14, the method includes step 306: scanning the case 14 to detect characteristics of the case 14 and the object 52 within the case 14. Finally, the method includes step 310: guiding the autonomous carrier 12 to transport the case 14 from the product delivery station 22 to a selected one of the two or more end-of-line case handling stations, at least in part based on the detected characteristic information.

[0051] The loading step 304 can include erecting the case 14 and placing the case 14 on the autonomous carrier 12 (e.g., for handling at the case delivery station 20). The scanning step 306 can include detecting one or more of the following: the height dimension of the case, the width dimension of the case, the depth dimension of the case, the height dimension of one or more objects in the case, non-conforming characteristics of the case, and the void volume of the case. The scanning step 306 can be repeated after the case 14 is transported to at least one end-of-line case handling station. The guiding step 310 can include instructions for bypassing at least one end-of-line case handling station.

[0052] The method can further include, for example, the step of selectively causing at least one of the one or more end-of-line case handling stations to perform at least one of the one or more end-of-line case handling operations on the case 14 by a system controller 40. When performing at least one of the one or more end-of-line case handling operations on the case 14, the case 14 can be located on the autonomous carrier 12.

[0053] The method can further include the step of detecting at least one characteristic of the case 14 and updating the route of the autonomous carrier 12 at least in part based on the detected characteristic. The detecting step can include identifying at least one detected characteristic that indicates the case 14 is non-conforming.

[0054] The method may further include the steps of transporting the container 14 to a plurality of end-of-line container processing stations, and performing one or more processing steps at the plurality of end-of-line container processing stations. Exemplary processing steps include providing padding to the container 14, forming flaps in the container 14, folding the flaps inwardly on the open side of the container 14, applying and securing a lid on the open side of the container 14, applying a shipping label to the container 14, and / or printing information directly on the container 14 or on a label pre-applied to the container 14.

[0055] In summary, the packaging system 10 for end-of-line container processing includes two or more end-of-line container processing stations 20, 22, 24, 26, 30, 34, and 36, each configured to perform one or more end-of-line processing operations. The packaging system 10 also includes an autonomous vehicle 12 and a controller 40. The container processing stations 20, 22, 24, 26, 30, 34, and 36 include a source of containers 14, a product delivery station 22 where an object 52 to be shipped is placed in the container 14, and sensors for detecting characteristics of the container 14 and the object 52 within the container 14. The autonomous vehicle 12 is configured to autonomously transport the container 14 from the product delivery station 22 to selected ones of the two or more container processing stations 24, 26, 30, 34, and 36. The controller 40 communicates with the sensors at the container scanning station 24 and the autonomous vehicle 12, and is configured to selectively direct the autonomous vehicle 12 to transport the container 14 from the product delivery station 22 to other selected ones of the two or more container processing stations 24, 26, 30, 34, and 36, at least in part based on information from the sensors at the scanning station 24.

[0056] Although the invention defined by the appended claims has been illustrated and described for particular embodiments, equivalent substitutions and modifications will occur to other persons skilled in the art upon reading and understanding this specification and the drawings. In particular, with respect to the various functions performed by the above-described overall (components, assemblies, devices, combinations, etc.), unless otherwise specified, the terms used to describe such overall (including references to "means") are intended to correspond to any overall (i.e., functionally equivalent) that performs the described functions of the overall shown in the exemplary embodiments of the invention herein, even if not structurally equivalent to the disclosed structure that performs the functions in the exemplary embodiments of the invention shown herein.

Claims

1. A packaging system for handling boxes at the end of a production line, the system comprising: Two or more end-of-production-line box handling stations, each of the end-of-production-line box handling stations configured to perform one or more end-of-production-line box handling operations, the end-of-production-line box handling stations including a source of boxes, a product delivery station for placing an object to be transported in the box, and a sensor for detecting characteristics of the box and the object in the box; An autonomous vehicle configured to autonomously transport the box from the product delivery station to a selected one of the two or more end-of-production-line box handling stations; And A controller operably communicating with the sensor and the autonomous vehicle, the controller configured to selectively direct the autonomous vehicle to autonomously transport the box from the product delivery station to another selected one of the two or more end-of-production-line box handling stations, at least in part based on information from the sensor.

2. The system according to claim 1, wherein The autonomous vehicle is an autonomous mobile robot.

3. The system according to claim 1 or 2, wherein, When at least one of the one or more end-of-production-line box handling operations is performed on the box, the box is located on the autonomous mobile robot.

4. The system according to claim 1 or any one of the preceding claims, wherein, The sensor is configured to detect at least one characteristic of the box, the characteristic including at least one of a height dimension, a width dimension, and a depth dimension.

5. The system according to claim 4 or any one of the preceding claims, wherein, At least one of the detected characteristics includes an indicator of non-conformance of the box.

6. The system according to claim 1 or any of the preceding claims, wherein, The controller is configured to direct the autonomous vehicle to automatically transport the box along a route bypassing at least one of the two or more end-of-production-line box handling stations.

7. The system according to claim 1 or any preceding claim, wherein, At least one of the two or more end-of-production-line box handling stations is automated.

8. The system according to claim 1 or any one of the preceding claims, wherein, At least one of the two or more end-of-production-line box handling stations includes a first end-of-production-line box handling station and a second end-of-production-line box handling station arranged remote from the first end-of-production-line box handling station such that the autonomous vehicle can be directed to a selected one of the first end-of-production-line box handling station and the second end-of-production-line box handling station, rather than the other of the first end-of-production-line box handling station and the second end-of-production-line box handling station.

9. The system according to claim 8 or any one of the preceding claims, wherein, The first end-of-production-line box handling station and the second end-of-production-line box handling station perform the same end-of-production-line box handling operations.

10. The system according to claim 8 or any one of the preceding claims, wherein, The first end-of-production-line box handling station and the second end-of-production-line box handling station perform different end-of-production-line box handling operations.

11. A method for handling boxes at the end of a production line, the method comprising the steps of: Providing a packaging system having two or more end-of-production-line box handling stations and one or more autonomous vehicles configured to move containers between selected ones of the two or more end-of-production-line box handling stations, the end-of-production-line box handling stations including a product delivery station at which an object to be transported is placed in the container for transportation; Load a container onto an autonomous vehicle to transport the container to a selected one of the two or more end-of-line bin handling stations; After placing an object to be transported in the container, scan the container to detect characteristics of the container and the object in the container; and Based at least in part on the detected characteristic information, guide the autonomous vehicle to transport the container along a route from the product delivery station to a selected one of the two or more end-of-line bin handling stations.

12. The method according to claim 11, further comprising selectively causing at least one of the one or more end-of-line bin handling stations to perform at least one of the one or more end-of-line bin handling operations on a bin.

13. The method according to claim 11 or 12, wherein, When performing at least one of the one or more end-of-line bin handling operations on the bin, the bin is located on the autonomous vehicle.

14. The method according to claim 11 or any one of claims 11 to 13, further comprising detecting at least one characteristic of the bin and updating the route based at least in part on the detected characteristic.

15. The method according to claim 11 or any one of claims 11 to 14, wherein The detecting step includes identifying at least one detected characteristic that indicates the bin is non-conforming.

16. The method according to claim 11 or any one of claims 11 to 15, wherein The guiding step includes an instruction to bypass at least one end-of-line bin handling station.

17. The method according to claim 11 or any one of claims 11 to 16, wherein, The loading step includes erecting the bin and placing the bin on the autonomous vehicle.

18. The method according to claim 11 or any one of claims 11 to 17, wherein The scanning step includes detecting one or more of the following: the height dimension of the bin, the width dimension of the bin, the depth dimension of the bin, the height dimension of one or more objects in the bin, non-conforming characteristics of the bin, and the void volume of the bin.

19. The method according to claim 11 or any one of claims 11 to 18, wherein After the bin is transported to at least one end-of-line bin handling station, repeat the scanning step.

20. The method according to claim 11 or any one of claims 11 to 19, further comprising the step of transporting the bin to a plurality of end-of-line bin handling stations.

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