Palletizer system and method

Abstract

A palletizer system (5) and method configured to automate the assembly of pallets in a compact space employs a turntable (7) including a conveyor (9) upon which a support base (28), various product arrays (48, 67, 71, 72) and a top support (74) are stacked by a first robotic mechanism (12) including an arm (16) provided with a transfer unit (18), preferably in the form of a vacuum or suction gripping surface. Concurrent with this building process, a second robotic mechanism (32) is employed to pick and position comer posts (57) within corner post receivers (55) provided on the turntable (7), with the turntable (7) being indexed as the first robotic mechanism (12) is shifted in connection with building the pallet. Once completed, the stacked product arrays (48, 67, 71, 72) are rotated on the turntable (7) while a film wrapper (40) wraps a film about the stacked product arrays (48, 67, 71, 72). Finally, the conveyor (9) of the turntable (7) is employed to transfer the completed palletized product (73) and the entire operation is repeated.

Description

PALLETIZER SYSTEM AND METHODFIELD OF THE INVENTION

[0001] The invention generally pertains to the art of packaging and, more specifically, to building a stack of products and wrapping the stacked products to create a pallet of products for shipping purposes.BACKGROUND OF THE INVENTION

[0002] It is common to palletize products for shipping from a manufacturing site to distribution and retail establishments. Often it is similar products which are stacked on a base and wrapped in film for stability and shipping purposes. Although palletizing products can be done manually, manufacturing plants typically employ automated systems for all the palletizing stages. More particularly, one or more conveyor systems are employed to deliver products to a stacking station wherein the products are arranged in arrays upon a base. Thereafter, the stacked products are transferred to a wrapping station where various stability and protective features, such as comer posts and wrapping, are typically added in preparation for transport. Movement of the pallets is often carried out using roller conveyors and forklifts.

[0003] A significant amount of manufacturing space needs to be dedicated to the palletizing process. Depending on the products being palletized, transporting the pallets between stations can be problematic. In particular, unless the product packaging can be stacked in a stable manner, transporting stacked products to a wrapping station can itself present production issues. To address these and other issues, advancements have been made in designing compact palletizing systems which basically enable many or all the stages to be performed in a single location, with the overall system having a smaller footprint. Still, further advancements in compact palletizing systems, particularly systems which can be used in palletizing unstable stackable products, are seen as needed.SUMMARY OF THE INVENTION

[0004] The present invention is directed to a palletizer system and method configured to automate the assembly of pallets in a compact space. The system and method have particular applicability in palletizing of unstable product arrays that require added protective features such as comer posts and top caps. In accordance with the invention, a pallet building support takes the form of a turntable including a conveyor. A supply conveyor directs products to a loading zone in which the products are arranged in a predetermined pallet array. A first robotic mechanism includes an arm provided with a transfer unit or gripper, preferably in the form of a vacuum or suction gripping surface, configured to build layers of the pallet on the turntable, with the pallet layers including a base support or cap, multiple vertically stacked product arrays and a top support or cap.

[0005] Concurrent with this building process, a second robotic mechanism is employed to grip and position comer posts within corner post receivers provided on the turntable. With the insertion of each corner post, which is initially arranged at an angle to the vertical, the turntable in accurately indexed with the use of a servo, such as 90°, while the first robotic mechanism is shifted in order to build another pallet array.

[0006] Once the requisite number of product arrays are stacked, a top support is placed on the multiple vertically stacked product arrays, extension flaps on the top support are folded, and the comer post receivers are shifted to reposition each corner post against the stacked product arrays. Thereafter, while the stacked product arrays remain on the turntable, a film wrapper is actuated, whereupon a film hand-off mechanism is employed to bring an end portion of a roll of wrapping material, e g., a clear stretch film, to a film holder mechanism mounted for rotation with the turntable and against the stacked product arrays. Once in position, the turntable is rotated while a film feeder is vertically repositioned to wrap the entire product stack. Finally, the turntable is aligned with a take-away conveyor unit, the conveyor of the turntable is activated to transfer the completed palletized product and the entire operation is repeated.

[0007] Based on the above, it should be readily apparent that the system and method of the invention enables a complete palletizing operation to be done in an automated fashion with avery small footprint. Other than being rotated on the turntable, the stacked product arrays are not moved until wrapped, such that the overall system and method can be advantageously employed in building even unstable club pallets requiring comer posts. Additional objects, features and advantages of the invention will become more readily apparent from the following detailed description of the invention when taken in conjunction with the drawings illustrating the stages of a palletizing operation wherein like reference numerals refer to corresponding parts in the several views.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure l is a view of a palletizer system constructed in accordance with the invention wherein products are supplied for a palletizing operation.

[0009] Figure 2 illustrates the initial depositing of a base support on a turntable by a first robotic mechanism in the construction of a pallet in accordance with the invention.

[0010] Figure 3 illustrates the placement of a first array of products on the base support.

[0011] Figure 4 shows a stage wherein extension flaps of the base support are folded.

[0012] Figure 5 depicts the shifting of corner post receivers carried by the turntable.

[0013] Figure 6 shows a stage wherein a comer post is inserted in a respective corner post receiver.

[0014] Figure 7 shows the turntable being indexed.

[0015] Figure 8 depicts the placement of a separator placed upon the first array of products.

[0016] Figure 9 shows a second product array being placed atop the first product array and the assembly being indexed.

[0018] Figure 10 depicts the insertion of the last comer post, a full product stack and a top support for the pallet.

[0019] Figure 11 depicts a preparation operation for stack wrapping.

[0020] Figure 12 shows a subsequent preparation stage.

[0021] Figure 13 shows an additional wrap preparation stage.

[0022] Figure 14 shows a mechanism positioned atop the stack with top support extension folding arms, as well as the final engagement of the corner post of the pallet, in further preparation for wrapping of the various product arrays.

[0023] Figure 15 presents an initial stage associated with film wrapping of the product stack.

[0024] Figure 16 illustrates the rotation of the turntable employed in wrapping the product stack.

[0025] Figure 17 depicts vertical movement of a film feeder in connection with wrapping the product stack.

[0026] Figure 18 shows progress of the wrapping operation to a lowermost portion of the product stack.

[0027] Figure 19 depicts a later wrapping stage operation of a film hand-off mechanism.

[0028] Figure 20 shows a final wrapping stage of the product stack.

[0029] Figure 21 illustrates the wrapped product stack and an initial extension stage for a transfer unit.

[0030] Figure 22 shows the wrapped product stack being shifted onto the transfer unit through activation of a conveyor of the turntable.

[0031] Figure 23 illustrates the overall assembly repositioned for a subsequent palletizing operation.DETAILED DESCRIPTION OF EMBODIMENTS

[0032] With initial reference to Figure 1, a palletizer system constructed in accordance with the present invention as generally indicated at 5. As will be detailed fully below, palletizer system 5 is configured to automate the assembly of pallets in a compact space. System 5 includes a turntable 7 which establishes a pallet body support having an upper surface defined by a conveyor 9. System 5 also includes a first robotic mechanism 12 including a rotatable base 14 and, as best shown in Figure 2, a multi-axis adjustable arm 16 which carries a transfer unit 18. In a preferred embodiment of the invention, transfer unit 18 takes the form of a vacuum or suctiongripping device, although other types of robotic transfer units known in the art could be employed.

[0033] A supply conveyor 22 is provided to direct products 24 to an area, not shown, which arranges products 24 in an array. In operation, system 5 activates transfer unit 18 which removes a base support 28, such as a sheet of cardboard having predetermined fold lines, from a magazine and places base support 28 on turntable 7. As clearly shown in Figure 2, base support 28 includes various peripheral extension flaps 30. System 5 also includes a second robotic mechanism 32 having a base 33 and a multi-axis adjustable arm 34 which carries a gripper 35. Gripper 35 of second robotic mechanism 32 is configured to pinch an object and manipulate the same as will be more fully detailed below. As also shown in this figure, system 5 includes a wrapping device 40 which, in the preferred embodiment, employs a film 42, such as a clear stretch film, such that wrapping device 40 establishes a film wrapper including upright holder bars 44 and 45 shown to be gripping a terminal end of film 42 and forming part of a film handoff mechanism as detailed fully below.

[0034] Referring to Figures 3 and 4, a first product array 48 has been picked up by transfer unit 18 and has been placed on base support 28. Once first product array 48 is positioned in this manner and transfer unit 18 has been shifted, a series of extension flap folding arms, two of which are indicated at 50 and 51, which are supported by turntable 7, are activated to fold extension flaps 30 against portions of first product array 48, thereby establishing a base cap for the pallet. Commensurate with or just subsequent to the activation of folding arms 50 and 51, comer post receivers, one of which is indicated at 55 and also carried by turntable 7, are pivoted so as to be arranged at an angle to the vertical as shown in Figure 5.

[0035] Figures 6 and 7 show a stage of the operation wherein a corner post 57 is taken by gripper 35 of second robotic mechanism 32 from a magazine 58 and positioned in an adjacent one of corner post receivers 55. Turntable 7 is then indexed, such as through 90°, whereupon a different corner post receiver 55 is positioned directly adjacent second robotic mechanism 32. By this time, as shown best in Figure 8, first robotic mechanism 12 has already lifted a separator or tier piece 63, also preferably formed of cardboard, and positioned the same atop first product array 48. Thereafter, first robotic mechanism 12 lifts a second product array 67 and positions thesame upon separator piece 63 above first product array 48 (see Figure 9). The process continues with turntable 7 being indexed, another comer post 57 being lifted and positioned in a respective comer post receiver 55 and first robotic mechanism 12 placing a third product array 71, another separate piece 63 and then a fourth product array 72 in place to achieve the full product stack 73 shown in Figure 10. Thereafter, first robotic mechanism 12 retrieves and positions a top support 74 upon product stack 73, with top support 74, like base support 28, including various extension flaps 76.

[0036] At this point, product stack 73 is to be wrapped in film 42 which will now be described with particular reference to Figures 11-20. As indicated above, film 42 is initially held between upright holder bars 44 and 45. In connection with a preparation operation for stack wrapping, turntable 7 is initially indexed until a base plate 82 attached to one side of turntable 7 is arranged directly adjacent wrapping device 40. From the position shown in Figure 11 to the position shown in Figure 12, further wrapping preparation has been performed wherein upright holder bars 44 and 45, which form part of a film hand-off mechanism, have shifted toward turntable 7 followed by the raising of gripper bars 85 and 86 which are attached for movement with base plate 82 and turntable 7. Once film 42 is held between gripper bars 85 and 86, holder bars 44 and 45 can be released to complete the preparatory transfer of film 42. In the exemplary embodiment shown, holder bar 44 pivots, while holder bar 45 is repositioned in a direction away from turntable 7, followed by the re-pivoting of holder bar 44 as shown best in Figure 13.

[0037] In the next operation phase, a third robotic mechanism 96 is positioned atop product stack 73 and extension folding arms 98 of third robotic mechanism 96 are actuated to fold extension flaps 76 of top support 74 down along product stack 73, thereby establish a top cap for the pallet. At the same time, comer post receivers 55 are pivoted such that comer posts 47 are positions against corners of product stack 73 as clearly shown in Figure 14. At this point, it should be recognized that product stack 73 was designed to be geometrically square so as to have four corners for corner posts 57. However, the particular geometric shape defined for product stack 73 can certainly vary in accordance with the invention and will depend particularly on the shape of products 24 supplied by conveyor 22 and the manner in which products 24 are arranged in the various arrays.

[0038] Figures 15-20 will now be referenced in describing a preferred wrapping operation in accordance with the invention. Turntable 7 starts to rotate and, due to the mounting of gripper bars 85 and 86 at base plate 82 as best shown in Figures 12-14, film 42 is pulled about product stack 73 (see Figure 15). At the same time, a film holder mechanism, generally indicated at 101, is vertically adjusted. With this operation, the continued rotation of turntable 7, while vertically shifting film holder mechanism 101, causes product stack 73 to be wrapped with film 42 from adjacent top support 74 to adjacent base support 28 as shown in Figures 16-18 respectively. Once product stack 73 is fully wrapped, turntable 7 is indexed to a position wherein base plate 82 is again directly opposite wrapping device 40. At this time, holder bar 44 is again pivoted upward, holder bar 45 is shifted into engagement with film 42 and holder bar 44 is then pivoted downward such that film 42 is sandwiched between holder bars 44 and 45 (see Figures 18 and 19). Thereafter, a film cutter unit 104, including a cutter such as a wire 105, is pushed against film 42 to cut the same as shown best in Figure 20 (also see Figures 17 and 18). At the same time, gripper bars 85 and 86 have pivoted back to their original, retracted positions.

[0039] With product stack 73 fully wrapped, the operation proceeds to that shown in Figure 21 wherein a take-away conveyor unit 114 is linearly shifted toward turntable 7. In the embodiment shown, take-away conveyor unit 114 includes a plurality of spaced legs 116 each of which incorporates a conveyor member shown in the form of a chain 117. Once legs 116 of take-away conveyor unit 114 reaches a desired position adjacent turntable 7, conveyor 9 of turntable 7 is activated, along with chains 117 of take-away conveyor unit 114, to cause product stack 73 to be shifted from turntable 7 onto take-away conveyor unit 114 as shown in Figure 22. This completes the palletizing operation and the overall assembly for a subsequent palletizing operation as shown in Figure 23.

[0040] With this overall system and method, a complete palletizing operation is performed in a fully automated fashion with the entire structure requiring a very small footprint, e.g., a 30’ x 30’ space or less in the depicted embodiment. As the stacked product arrays are only rotated on a very stabilized turntable, the palletizer system of the invention can be advantageously employed in building even unstable club pallets. That is, the invention advantageously functions to build and stabilize before any significant moving of the assembledpallet. Although not discussed in detail, it should be understood that the operation of the various components of system 5 are linked to a common controller or CPU which is programmed to repeatedly synchronize the operational stages detailed above. In assuring precise component positioning, servo controlled systems are preferably employed, e.g., the turntable is servo controlled for precise indexing. In connection with both the product stacking and wrapping operations, the inclusion of the hand-off mechanism advantageously allows turntable 7 to freely rotate during product stacking, while also effectively holding an end of the film during wrapping. Although each of the rotatable turntable, the corner post mounting arrangement and the film hand-off mechanism present individual advancements in connection with performing a palletizing operation in a compact area, collectively they have a synergistic effect.

Claims

CLAIMS:

1. An automated palletizer system configured to assemble pallets comprising: a turntable configured to be rotated; a first robotic mechanism configured to assemble a pallet, including at least a base support and a plurality of stacked, product arrays, on the turntable, said first robotic mechanism including an arm supporting a transfer unit configured to stack the plurality of product arrays upon the base support; and a film wrapping device including a gripper assembly attached for rotation with the turntable, wherein a film held by the gripper assembly is wrapped around the pallet upon rotating the turntable.

2. The automated palletizer system of claim 1, wherein the gripper assembly includes a pair of gripper bars configured to sandwich the film therebetween.

3. The automated palletizer system of claim 1 or 2, wherein the film wrapping device further includes a film handoff mechanism configured to support the film during assembly of the pallet by the first robotic mechanism and then transfer the film to the gripper assembly for wrapping the pallet in the film.

4. The automated palletizer system of claim 3, wherein the film wrapping device further includes a cutter unit configured to be activated to cut the film upon wrapping the pallet.

5. The automated palletizer system of claim 1 or 2, further comprising a second robotic mechanism configured to position corner posts within comer post receivers provided about the plurality of product arrays on the turntable.

6. The automated palletizer system of claim 5, wherein the comer post receivers are pivotally attached to the turntable and configured to shift against the plurality of product arraysafter stacking the plurality of product arrays upon the base support and before wrapping the pallet.

7. The automated palletizer system of claim 1 or 2, further comprising flap folding arms carried by the turntable configured to be selectively shiftable to pivot extension flaps of the base support about a lowermost one of the plurality of product arrays.

8. The automated palletizer system of claim 7, further comprising a third robotic mechanism including a body member configured to be positioned atop the pallet and including arms configured to fold extension flaps of a top support positioned atop the plurality of product arrays by the first robotic mechanism.

9. The automated palletizer system of claim 1 or 2, wherein the turntable includes a base defined by a conveyor configured to transfer the pallet from the turntable after being wrapped.

10. The automated palletizer system of claim 9, further comprising an extensible transfer unit configured to be automatically shifted relative to the turntable to receive the pallet from the turntable after wrapping of the pallet.

11. A method of assembling pallets in an automated process comprising: operating a first robotic mechanism to assemble a pallet, including at least a base support and a plurality of stacked, product arrays, on a turntable, said first robotic mechanism employing an arm supporting a transfer unit configured to stack the plurality of product arrays upon the base support; and wrapping a film around the pallet upon rotating the turntable by holding the film with a gripper assembly attached for rotation with the turntable.

12. The method of claim 11, wherein the turntable is indexed between the stacking of the plurality of product arrays upon each other.

13. The method of claim 12, wherein indexing the turntable constitutes rotating the turntable through 90°.

14. The method of claim 11 or 12, further comprising transferring the film from a film handoff mechanism which supports the film during assembly of the pallet to a gripper assembly attached for rotation with the turntable in wrapping the pallet.

15. The method of claim 14, further comprising cutting the film upon wrapping the pallet and again supporting the film with the film handoff mechanism instead of the gripper assembly.

16. The method of claim 11 or 12, further comprising position comer posts within corner post receivers provided about the plurality of product arrays on the turntable with a second robotic assembly.

17. The method of claim 16, further comprising pivoting the comer post receivers relative to the turntable to shift the comer posts against the plurality of product arrays after stacking the plurality of product arrays upon the base support and before wrapping the pallet.

18. The method of claim 11 or 12, further comprising shifting flap folding arms carried by the turntable to pivot extension flaps of the base support about a lowermost one of the plurality of product arrays.

19. The method of claim 11 or 12, further comprising positioning a body member of a third robotic atop the pallet to fold extension flaps of a top support positioned atop the plurality of product arrays by the first robotic mechanism.

20. The method of claim 11 or 12, activating a conveyor of the turntable to transfer the pallet from the turntable after being wrapped.

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