Case sealer and method of operating a case sealer

Abstract

The present disclosure provides a case sealer including a frame, a top-head assembly including a tape cartridge configured to support a tape roll, one or more top-head-assembly actuators operably connected to the top-head assembly and configured to move the top-head assembly relative to the frame, and a controller. The controller controls the top-head-assembly actuators to raise the top-head assembly and, after a case has been positioned beneath the top-head assembly, controls the top-head assembly actuators to exert a resistive force on the top-head assembly such that the top-head assembly lowers onto the case. The resistive force is a first resistive force when the weight of the tape roll is a first weight and a second resistive force when the weight of the tape roll is a second weight. The first weight is greater than the second weight, and the first resistive force is greater than the second resistive force.

Description

CASE SEALER AND METHOD OF OPERATING A CASE SEALERPriority

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 512,991, filed July 11, 2023, the entire contents of which is incorporated herein by reference.Field

[0002] The present disclosure relates to case sealers, and more particularly to random case sealers configured to seal cases of different heights.Background

[0003] Every day, companies around the world pack millions of items in cases, such as corrugated boxes, to prepare them for shipping. Case sealers help automate this process by applying pressure-sensitive tape to cases already packed with items to seal those cases shut. Random case sealers automatically adjust to the height of each case so they can seal cases of different heights without requiring the operator to reconfigure the machine. A typical random case sealer includes a frame including two lower drive belts, a lower tape cartridge removably mounted to the frame between the lower drive belts, a mast mounted to the frame, and a top-head assembly movably mounted to the mast. The top-head assembly includes two upper drive belts, an upper tape cartridge, and a pressure switch. The lower tape cartridge applies tape to the leading, bottom, and trailing surfaces of the case as the upper and lower drive belts move the case past the lower tape cartridge, and the upper tape cartridge applies tape to the leading, upper, and trailing surfaces of the case as the upper and lower drive belts move the case past the upper tape cartridge.

[0004] To seal a case using a random case sealer, an operator moves the case into engagement with the pressure switch. In response, an actuator begins raising the top-head assembly. Once the top-head assembly ascends above the case so the case stops contacting the pressure switch, the operator moves the case beneath the top-head assembly and holds it there.At the same time, the actuator exerts a resistive force on the top-head assembly that is lower than the weight of the top-head assembly such that the top-head assembly descends toward the case. Once the upper drive belts of the top-head assembly contact the top surface of the case, the operator releases the case and the drive belts move the case past relative to the tape cartridges, which apply tape to the case as the case moves past the tape cartridges.

[0005] The tape cartridges include multiple components that cooperate to apply tape to the case. For instance, each tape cartridge includes multiple rollers that force the tape onto multiple surfaces of the case, a cutter that cuts the tape from a tape supply (such as a roll of tape), and a brush that extends past the drive belt and into the path of the case near the downstream end of the tape cartridge. As the case moves past the tape cartridges, the brush engages and forces the tape into contact with the case to promote good adhesion.

[0006] Certain known case sealers are configured such that the downward force exerted by the top-head assembly as it descends and engages the upper surface of the case does not exceed a predetermined target force. The top-head assembly is heaviest just after a new tape roll is loaded onto the tape cartridge. The resistive force the actuator exerts on the top-head assembly is set to partially counteract the weight of the top-head assembly at its heaviest such that the downward force does not exceed the target force. As the case sealers apply tape to cases, the tape roll — and therefore the top-head assembly supporting the tape roll — becomes progressively lighter. Since these known case sealers maintain a static resistive force, the tophead assembly descends more slowly as tape is used, which increases cycle time and decreases throughput.Summary

[0007] Various embodiments of the present disclosure provide a case sealer including a frame, a top-head assembly including a tape cartridge configured to support a tape roll, one or more top-head-assembly actuators operably connected to the top-head assembly and configured to vertically move the top-head assembly relative to the frame, and a controller. The controller is configured to control the one or more top-head-assembly actuators to raise the tophead assembly and, after a case has been positioned beneath the top-head assembly, control the one or more top-head assembly actuators to exert a resistive force on the top-head assembly suchthat the top-head assembly lowers into engagement with the case. The resistive force is a first resistive force when the weight of the tape roll is a first weight and a second resistive force when the weight of the tape roll is a second weight. The first weight is greater than the second weight, and the first resistive force is greater than the second resistive force.Brief Description of the Figures

[0008] Figure l is a perspective view of one example embodiment of a case sealer of the present disclosure.

[0009] Figure 2 is a block diagram showing certain components of the case sealer of Figure 1.

[0010] Figure 3 is a perspective view of the mast assembly of the case sealer of Figure 1.

[0011] Figure 4 is a perspective view of the top-head assembly of the case sealer of Figure 1.

[0012] Figures 5A-5H are various views of the tape cartridge of the case sealer of Figure 1 and its components.

[0013] Figures 6A-6I are side views of the case sealer of Figure 1 sealing a case. Certain portions of the mast assembly removed for clarity.

[0014] Figure 7 is a flowchart of one example method of operating the case sealer of Figure 1.

[0015] Figure 8 is identical to Figure 6A but with a smaller tape roll.Detailed Description

[0016] While the systems, devices, and methods described herein may be embodied in various forms, the drawings show and the specification describes certain exemplary and nonlimiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connection of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, anydirections referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as coupled, mounted, connected, etc., are not intended to be limited to direct mounting methods, but should be interpreted broadly to include indirect and operably coupled, mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

[0017] Figure 1-61 show one example embodiment of a case sealer 10 of the present disclosure and components thereof. The case sealer 10 includes a base assembly 100, a mast assembly 300, a top-head assembly 400, a lower tape cartridge 1000a, and an upper tape cartridge 1000b. As shown in Figure 2, the case sealer 10 also includes multiple actuating assemblies and actuators operably connected to and configured to control movement of certain components of the case sealer 10; multiple sensors S1-S6; and control circuitry and systems for controlling the actuating assemblies and the actuators (and other mechanical, pneumatic, electromechanical, and electrical components of the case sealer 10) responsive to signals received from the sensors S.

[0018] The case sealer 10 also includes a controller 90 communicatively connected to the sensors S to send and receive signals to and from the sensors S. The controller 90 is operably connected to the actuating assemblies and the actuators to control the actuating assemblies and the actuators. The controller 90 may be any suitable type of controller (such as a programmable logic controller) that includes any suitable processing device(s) (such as a microprocessor, a microcontroller-based platform, an integrated circuit, or an applicationspecific integrated circuit) and any suitable memory device(s) (such as random access memory, read-only memory, or flash memory). The memory device(s) stores instructions executable by the processing device(s) to control operation of the case sealer 10.

[0019] The base assembly 100 is configured to align cases in preparation for sealing and to — along with the top-head assembly 400 — move the cases through the case sealer 10. The base assembly 100 supports the lower tape cartridge 1000a and the mast assembly 300, which in turn supports the top-head assembly 400 that includes the upper tape cartridge 1000b. The base assembly 100 includes a base-assembly frame 111, an infeed table 112, an outfeed table 113, a side-rail assembly, and a lower drive assembly. The base assembly 100 defines an infeed end IN(Figure 1) of the case sealer 10 at which an operator (such as a person or an automated casefeeding system) feeds incoming cases into the case sealer 10 (via the infeed table 112) and an outfeed end OUT (Figure 1) of the case sealer 10 at which the case sealer 10 ejects cases onto the outfeed table 113.

[0020] The base-assembly frame I l l is configured to support various components of the case sealer 10 and is formed from any suitable combination of solid and / or tubular members and / or plates fastened together. The infeed table 112 is mounted to the base-assembly frame 111 adjacent the infeed end IN of the case sealer 10. The infeed table 112 includes multiple rollers on which the operator can place a case and then use to convey the case toward the top-head assembly 400. The infeed table 112 includes an infeed-table sensor SI (Figure 2), which may be any suitable sensor (such as a photoelectric sensor) configured to detect the presence of a case on the infeed table 112 and, more particularly, the presence of a case at a particular location on the infeed table 112 that corresponds to the location of the infeed-table sensor SI. In other embodiments, another component of the case sealer 10 includes the infeed-table sensor SI. The infeed-table sensor SI is communicatively connected to the controller 90 to send signals to the controller 90 responsive to detecting a case (a case-detected signal) and, afterwards, no longer detecting the case (a case-undetected signal), as described below. The outfeed table 113 is mounted to the base-assembly frame 111 adjacent the outfeed end OUT of the case sealer 10. The outfeed table 113 includes a generally planar surface onto which the case is ejected after moving past the tape cartridges, though it may include multiple rollers in other embodiments.

[0021] The side-rail assembly is supported by the base-assembly frame 111 adjacent the infeed table 112 and includes first and second side rails 114a and 114b (Figure 1) and a siderail actuator 117 (Figure 2). The side rails 114a and 114b extend generally parallel to a direction of travel D (Figure 1) of a case through the case sealer 10 and are movable laterally inward (relative to the direction of travel D) to laterally center the case on the infeed table 112. The siderail actuator 117 is operably connected to the first and second side rails 114a and 114b (either directly or via suitable linkages) to move the side rails between: (1) a rest configuration (Figure 1) in which the side rails are positioned at or near the lateral extents of the infeed table 112 to enable an operator to position a case between the side rails on the infeed table 112; and (2) a centering configuration (not shown) in which the side rails — after being moved toward one another — contact the case and center the case on the infeed table 112. The controller 90 isoperably connected to the side-rail actuator 117 to control the side-rail actuator 117 to move the side rails 114a and 114b between the rest and centering configurations. The side-rail actuator 117 may be any suitable type of actuator, such as a motor or a pneumatic cylinder fed with pressurized gas and controlled by one or more valves.

[0022] The lower drive assembly is supported by the base-assembly frame 111 and (along with an upper drive assembly 420, described below) configured to move cases in the direction D. The lower drive assembly includes first and second lower drive elements and (though it may include only one drive element or more than two drive elements in other embodiments) and a lower-drive-assembly actuator 118 operably connected to the first and second lower drive elements and configured to drive the first and second lower drive elements to (along with the upper drive assembly 420) move cases through the case sealer 10. In this example embodiment, the lower-drive-assembly actuator 118 includes a motor that is operably connected to the first and second lower drive elements and — which include endless belts in this example embodiment — via one or more other components, such as sprockets, gearing, screws, tensioning elements, and / or a chain. The lower-drive-assembly actuator may include any other suitable actuator in other embodiments. The first and second lower drive elements and may include any other suitable component or components, such as rollers, in other embodiments. The controller 90 is operably connected to the lower-drive-assembly actuator 118 to control operation of the lower-drive-assembly actuator 118.

[0023] The lower drive assembly supports a case-entry sensor S3 downstream of the infeed table 112, downstream of the leading-surface sensor S2 (described below), and beneath the top-head assembly 400 so the case-entry sensor S3 can detect when a case enters the area below the top-head assembly 400. As used herein, “downstream” means in the direction of travel D, and “upstream” means the direction opposite the direction of travel D. Also, unless explicitly stated otherwise, “above” and “below” as used herein mean “in a plane above” and “in a plane below” and not “directly above” or “directly below.” The case-entry sensor S3 includes a proximity sensor (or any other suitable sensor, such as a mechanical sensor) configured to detect the presence of a case. In other embodiments, the case-entry sensor S3 is supported by the mast assembly 300 or the top-head assembly 400. The case-entry sensor S3 is communicatively connected to the controller 90 to send signals to the controller 90 responsive to detecting the case (a case-detected signal) and no longer detecting the case (a case-undetected signal).

[0024] The base-assembly frame 111 supports a case-exit sensor S5 that includes a proximity sensor (or any other suitable sensor) configured to detect the presence of a case. Here, although not shown, the case-exit sensor S5 is positioned near the outfeed table 113 (downstream of the case-entry and arm-retraction sensors S3 and S4 described below) so the case-exit sensor S5 can detect when a case exits from beneath the top-head assembly 400. The case-exit sensor S5 is communicatively connected to the controller 90 to send signals to the controller 90 responsive to detecting the case (a case-detected signal) and no longer detecting the case (a case- undetected signal). In other embodiments, the case-exit sensor S5 is part of the top-head assembly 400.

[0025] The mast assembly 300, which is best shown in Figure 3, is configured to support and control vertical movement of the top-head assembly 400 relative to the base assembly 100. The mast assembly 300 includes first and second top-head-assembly mounts 310 and 350 and a top-head-actuating assembly 390 that includes one or more top-head-actuatingassembly actuators 395 operably connected to the top-head assembly 400 and configured to move the top-head assembly 400 toward and away from the base assembly 100.

[0026] The first top-head-assembly mount 310 includes an enclosure 315, first and second rails 320 and 330, and a carriage 340. The enclosure 315 defines a volume in which the first and second rails 320 and 330 are mounted vertically and substantially parallel to one another. The carriage 340 is slidably mounted to the first and second rails 320 and 330. The second top-head-assembly mount 350 is identical to the first top-head-assembly mount 310 and not separately described. The top-head-actuating-assembly actuators 395 are operably connected to the carriages of the first and second top-head-assembly mounts 310 and 350 and configured to move them vertically. In this example embodiment, the top-head-assembly actuators 395 include pneumatic cylinders fed with pressurized gas and controlled by one or more valves, though they may be any other suitable type of actuator (such as a motor) in other embodiments. The controller 90 is operably connected to the top-head-assembly actuator(s) 395 to control vertical movement of the top-head assembly 400.

[0027] The top-head assembly 400 is movably supported by the mast assembly 300 to adjust to cases of different heights and is configured to move the cases through the case sealer 10, engage the top surfaces of the cases while doing so, and support the upper tape cartridge 1000b. As best shown in Figures 2 and 4, the top-head assembly 400 includes a top-head-assembly frame 410, an upper drive assembly 420, a leading-surface sensor S2, an arm -retraction sensor S4, and a tape-roll sensor S6. In other embodiments, one or more other components of the case sealer 10 (such as the base assembly 100 and / or the mast assembly 300) include the one or more of the sensors S2, S4, and S6.

[0028] The top-head-assembly frame 410 is configured to be mounted to the slidable carriages of the first and second top-head-assembly mounts 310 and 350 of the mast assembly 300 and to support the other components of the top-head assembly 400. The top-head-assembly frame 410 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 and 414 that are respectively connected to the slidable carriages of the first and second top-head-assembly mounts 310 and 350 of the mast assembly 300.

[0029] The upper drive assembly 420 is supported by the top-head-assembly frame 410 and (along with the lower drive assembly described above) configured to move cases in the direction D. The upper drive assembly 420 includes an upper drive element (or in other embodiments multiple upper drive elements) and an upper-drive-assembly actuator 422 (Figure 2) operably connected to the upper drive element to drive the upper drive element to (along with the lower drive assembly) move cases through the case sealer 10. In this example embodiment, the upper-drive-assembly actuator 422 includes a motor that is operably connected to the upper drive element — which includes an endless belt in this example embodiment — via one or more other components, such as sprockets, gearing, screws, tensioning elements, and / or a chain. The upper-drive-assembly actuator 422 may include any other suitable actuator in other embodiments. The upper drive element may include any other suitable component or components, such as rollers, in other embodiments. The controller 90 is operably connected to the upper-drive-assembly actuator 422 to control operation of the upper-drive-assembly actuator 422.

[0030] The leading-surface sensor S2 includes a mechanical paddle switch (or any other suitable sensor, such as a proximity sensor) positioned at a front end of the top-head- assembly frame 410 and configured to detect when the leading surface of a case initially contacts (or is within a predetermined distance of) the top-head assembly 400. The leading-surface sensor S2 is communicatively connected to the controller 90 to send signals to the controller 90 responsive to actuation (a case-detected signal) and de-actuation (a case-undetected signal) of theleading-surface sensor S2 (corresponding to the leading-surface sensor S2 detecting and no longer detecting the case and / or an object).

[0031] The arm-retraction sensor S4 includes a proximity sensor (or any other suitable sensor) configured to detect the presence of a case. Here, although not shown, the armretraction sensor S4 is positioned on the underside of the top-head-assembly frame 410 downstream of the case-entry sensor S3 so the arm-retraction sensor S4 can detect when a case reaches a particular position underneath the top-head assembly 400 (here, a position just before the case contacts the front rollers of the tape cartridges, as explained below). The arm-retraction sensor S4 is communicatively connected to the controller 90 to send signals to the controller 90 responsive to detecting the case (a case-detected signal) and no longer detecting the case (a case- undetected signal).

[0032] The tape-roll sensor S6 is configured to sense a characteristic associated with the tape roll. The tape-roll sensor S6 is communicatively connected to the controller 90 and configured to periodically send signals to the controller 90 indicative of the sensed characteristic. As described below, the controller 90 is configured to use the sensed characteristic to determine the resistive force to exert on the top-head assembly 400 as it descends onto the top surface of the case. In this example embodiment, the tape-roll sensor S6 includes an ultrasonic, laser, or other suitable type of sensor positioned and otherwise configured to detect a distance between itself and an outer surface of the tape roll of the upper tape cartridge 1000b. As described below, the controller 90 is configured to use this information to determine the weight of the tape roll. In other embodiments, the tape-roll sensor includes a mass or weight sensor configured to directly sense the mass or weight of the tape roll or the top-head assembly. In further embodiments, the tape-roll sensor includes a spring-loaded encoder positioned to physically contact the outer surface of the tape roll and generate feedback when the diameter of the tape roll changes. The tape-roll sensor may be included in any suitable assembly of the case sealer.

[0033] The controller 90 is operably connected to: (1) the top-head-actuating assembly 395 and configured to control the top-head-actuating assembly 395 to control vertical movement of the top-head assembly 400 responsive to signals received from the sensors S2, S3, S5, and S6; and (2) the lower tape cartridge 1000a and the upper tape cartridge 1000b and configured to control the force-reduction functionality of these tape cartridges responsive tosignals received from the arm -retraction sensor S4, as described in detail below in conjunction with Figures 5A-5H.

[0034] The lower tape cartridge 1000a is configured to apply tape to a leading surface, a bottom surface, and a trailing surface of the case, and the upper tape cartridge 1000b is configured to apply tape to the leading surface, a top surface, and the trailing surface of a case. In this example embodiment, the lower and upper tape cartridges are identical and referred to in the accompanying description as the “tape cartridge.”

[0035] The tape cartridge 1000 includes a first mounting plate Ml 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, a tape-cartridge-actuating assembly 1600, and a wipe-down element 1900. As best shown in Figure 6A, a second mounting plate M2 is mounted to the first mounting plate Ml via multiple spacer 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, the tape-cartridge-actuating assembly 1600, and the wipe-down element 1900 therebetween.

[0036] The front roller assembly 1100 includes a front roller arm 1110 and a front roller 1120. The front roller arm 1110 is pivotably mounted to the first mounting plate Ml via a front roller-arm-pivot shaft PSFRONT SO the front roller arm 1110 can pivot relative to the mounting plate Ml about an axis between a front roller arm extended position (Figures 6A-6C) and a front roller arm retracted position (Figure 6D). The front roller arm 1110 includes a front roller-mounting shaft 1120a, and the front roller 1120 is rotatably mounted to the front rollermounting shaft 1120a so the front roller 1120 can rotate relative to the front roller-mounting shaft 1120a.

[0037] The rear roller assembly 1200 includes a rear roller arm 1210 and a rear roller 1220. The rear roller arm 1210 is pivotably mounted to the first mounting plate Ml via a rear roller-arm-pivot shaft PSREAR SO the rear roller arm 1210 can pivot relative to the mounting plate Ml about an axis AREAR between a rear roller arm extended position (Figures 6A-6C) and a rear roller arm retracted position (Figure 6D). The rear roller arm 1210 includes a rear rollermounting 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.

[0038] A rigid first linking member 1020 is attached to and extends between the first roller arm 1110 and the second roller arm 1210. The first linking member 1020 links the front and rear roller assemblies 1100 and 1200 so: (1) moving the front roller arm 1110 from the front roller arm extended position to the front roller arm retracted position causes the first linking 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 linking 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).

[0039] The tape-cartridge-actuating assembly 1600 (Figure 2) includes a roller-arm- actuating assembly 1700 and a cutter-arm-actuating assembly 1800.

[0040] The roller-arm-actuating assembly 1700 is configured to move the linked front and rear roller arms 1110 and 1210 between their respective extended and retracted positions. As best shown in Figure 6G, in this example embodiment the roller-arm-actuating assembly 1700 includes a support plate 1702 and a roller-arm actuator 1710 pivotably attached to the support plate 1702 via a pin assembly 1703. The roller-arm actuator 1710 may be any suitable actuator, such as a motor or a pneumatic cylinder fed with pressurized gas and controlled by one or more valves.

[0041] The roller-arm actuator 1710 is operably connected to the front roller assembly 1100 to control movement of the front roller arm 1110 and the rear roller arm 1210 linked to the front roller arm 1110 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 via attachment of the support plate 1702 to the mounting plate M2 and attachment of the roller-arm actuator 1710 to the shaft 1130 of the front roller assembly 1100.

[0042] The controller 90 is operably connected to the roller-arm actuator 1710 and configured to control the roller-arm actuator 1710 and therefore the positions of the front and rear roller arms 1110 and 1210.

[0043] As best shown in Figures 6E and 6F, the cutter assembly 1300 includes a cutter arm 1301, a cutting-device cover pivot shaft 1306, a cutter-arm-actuator-coupling element 1310, a cutting-device-mounting assembly 1320, a cutting device 1330 including a toothed blade(not labeled) configured to sever tape, a cutting-device cover 1340, a cutting-device pad 1350, and a rotation-control plate 1360.

[0044] The cutter arm 1301 includes a cylindrical surface 1301a that defines a cutter arm mounting opening. The cutter arm 1301 is pivotably mounted (via the cutter arm mounting opening) to the first mounting plate Ml via the front roller-arm-pivot shaft PSFRONT and bushings 1303a and 1303b so the cutter arm 1301 can pivot relative to the mounting plate Ml about the axis between a cutter arm extended position (Figures 6A-6C) and a cutter arm retracted position (Figure 6D).

[0045] 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.

[0046] The cutting-device-mounting assembly 1320 is fixedly mounted to the support arm 1301 (such as via welding) and is configured to removably receive the cutting device 1330. That is, the cutting-device-mounting assembly 1320 is configured so 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, though any other suitable cutting-device-mounting assembly may be used to support the cutting device 1330.

[0047] 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 pivotably mounted to the support arm 1301 via mounting openings (not labeled) and the cutting-device cover pivot shaft 1306. Once attached, the cutting-device cover 1340 is pivotable about an axis relative to the cutter arm 1301 and the cutting-device-mounting assembly 1320 from front to back and back to front between a closed position and an open position. A cutting-device cover biasing element 1346, which includes a torsion spring in this example embodiment, biases the cutting-device cover 1340 to the closed position. When in the closed position, the cutting-device cover 1340 generally encloses the cutting device 1330 so 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.

[0048] The cutting-device cover pivot shaft 1306 is also attached to the rotationcontrol plate 1360. The rotation-control plate 1360 includes a slot-defining surface 1362 that defines a slot. The surface 1362 acts as a guide (not shown) for a bushing that is attached to themounting plate M2. The bushing provides lateral support for the cutter assembly 1300 to generally prevent the cutter assembly 1300 from moving toward or away from the mounting plates Ml and M2 and interfering with other components of the tape cartridge 1000 when in use.

[0049] The cutter-arm-actuating assembly 1800 is configured to move the cutter arm 1301 between its retracted position and its extended position. As best shown in Figure 6H, in this example embodiment the cutter-arm-actuating assembly 1800 includes a cutter-arm actuator 1810. The cutter-arm actuator 1810 may be any suitable actuator, such as a motor or a pneumatic cylinder fed with pressurized gas and controlled by one or more valves.

[0050] The cutter-arm actuator 1810 is operably connected to the cutter assembly 1300 to control 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 Ml and the cutter assembly 1300 via attachment to the shaft 1610 and to the coupling shaft 1314 of the cutter-arm-actuator-coupling element 1310.

[0051] The controller 90 is operably connected to the cutter-arm actuator 1810 and configured to control the cutter-arm actuator 1810 and therefore the position of the cutter arm 1301.

[0052] The tape-mounting assembly 1400 includes a tape-mounting plate 1410 and a tape-core-mounting assembly 1420 rotatably mounted to the tape-mounting plate 1410. The tape- core-mounting assembly 1420 is further described in U.S. Patent No. 7,819,357 (though other tape core mounting assemblies may be used in other embodiments). A roll R of tape is mountable to the tape-core-mounting assembly 1420.

[0053] The tension-roller assembly 1500 includes several rollers (not labeled) rotatably disposed on shafts that are supported by the first mounting plate Ml. A free end of the roll R of tape mounted to the tape-core-mounting assembly 1420 is threadable through the rollers until the free end is adjacent the front roller 1120 of the front-roller assembly 1100 with its adhesive side facing outward in preparation for adhesion to a case. The tension-roller assembly 1500 is further described in U.S. Patent No. 7,937,905 (though other tension roller assemblies may be used in other embodiments).

[0054] The wipe-down element 1900 includes a base 1910 and one or more deformable elements 1920 connected to the base 1910. The base 1910 is fixedly mounted to and extends between the first and second mounting plates Ml and M2 downstream of the rear rollerassembly 1200. The wipe-down element 1900 is oriented so the deformable elements 1920 extend toward the roller 1220 when the rear roller arm 1210 is in the rcar-roller-arm extended position. The deformable elements 1920 are rigid enough to return to their original shape when no force is applied to them yet compliant enough to deform when sufficient force is applied to them, such as when a case is forced against them as described below. In this example embodiment, the deformable elements 1920 are bristles, though they may be any suitable elements in other embodiments (such as foam or rubber elements).

[0055] The lower tape cartridge 1000a is removably mounted to the base assembly 100 and configured to apply tape to the leading surface, the bottom surface, and the trailing surface of the case. The upper tape cartridge 1000b is removably mounted to the top head assembly 400 in any suitable manner and is configured to apply tape to a leading surface, a top surface, and a trailing surface of a case.

[0056] Operation of the case sealer 10 is now described in conjunction with Figures 6A-6I. Initially, the top-head assembly 400 is at its initial lower position; the side rails 114a and 114b are in their rest configuration; the front roller arm 1110, the rear roller arm 1210, and the cutter arm 1301 of the lower tape cartridge 1000a are in their respective extended positions; and the front roller arm 1110, the rear roller arm 1210, and the cutter arm 1301 of the upper tape cartridge 1000b are in their respective extended positions. The controller 90 controls the lower- drive-assembly actuator 118 and the upper-drive-assembly actuator 422 to drive the first and second lower drive elements of the base assembly 100 and the upper drive element of the tophead assembly 400, respectively.

[0057] The operator positions a case C on the infeed table 112, as shown in Figure 6A. The infeed-table sensor S 1 detects the presence of the case and in response sends a corresponding case-detected signal to the controller 90. Responsive to receiving that case- detected signal, the controller 90 controls the side -rail actuator 117 to move the side rails 114a and 114b from the rest configuration to the centering configuration so the side rails 114a and 114b move laterally inward to engage and center the case on the infeed table 112.

[0058] The operator then moves the case into contact with the leading-surface sensor S2, as shown in Figure 6B. This causes the leading-surface sensor S2 (via the case contacting and actuating the paddle switch of the leading-surface sensor S2) to detect the case and in response send a corresponding case-detected signal to the controller 90. Responsive to receivingthe case-detected signal, the controller 90 controls the top-head-actuating assembly 390 (and, more particularly, the top-head-actuating-assembly actuator(s) 395) to begin raising the top-head assembly 400. As the top-head assembly 400 moves upward, the leading-surface sensor S2 eventually stops detecting the case, as shown in Figure 6C. This indicates that the top-head assembly 400 has ascended above the top surface of the case. In response to no longer detecting the case, the leading-surface sensor S2 sends a corresponding case-undetected signal to the controller 90. Responsive to receiving that signal, the controller 90 controls the top-head- actuating assembly 390 (and more particularly the top-head-actuating-assembly actuator(s) 395) to enable the top-head assembly 400 to stop its ascent and begin descending.

[0059] Specifically, the controller 90 controls the top-head-actuating-assembly actuator(s) 395 to exert a resistive force on the top-head assembly 400 that partially counteracts the weight of the top-head assembly 400 such that the top-head assembly 400 lowers into engagement with the case C. The controller 90 is configured to do so such that the downward force the top-head assembly 400 exerts on the case C is equal or substantially equal to a predetermined target force regardless of the weight of the top-head assembly 400. As tape is used during sealing processes, the weight of the tape roll of the upper tape cartridge 1000b and therefore the weight of the top-head assembly 400 decreases over time. For instance, the tape roll shown in Figure 8 is substantially smaller — and lighter — than the tape roll shown in Figure 6 A. To ensure the downward force the top-head assembly 400 exerts on the case C is equal or substantially equal to the target force throughout the life of the tape roll, the controller 90 decreases the resistive force as tape is used and the weight top-head assembly 400 decreases. For instance, the target force is 100 Newtons. With a full tape roll, the top-head assembly weighs 1,000 Newtons. In this instance, the controller would control the top-head-actuating-assembly actuator(s) to exert a resistive force of 900 Newtons on the top-head assembly so the resultant downward force of the top-head assembly is the target force of 100 Newtons. With a half- full tape roll, the top-head assembly weighs 985 Newtons. In this instance, the controller would control the top-head-actuating-assembly actuator(s) to exert a resistive force of 885 Newtons on the top-head assembly so the resultant downward force of the top-head assembly is the target force of 100 Newtons.

[0060] The controller 90 is configured to determine the resistive force based on the characteristic associated with the tape roll that is sensed by the tape-roll sensor S6. This sensedcharacteristic is indicative of a weight of the tape roll and associated with a corresponding resistive force. How the controller does so is based at least in part on the type of sensor. In certain embodiments, the tape-roll sensor is configured to sense the weight (or mass) of the tape roll. In other embodiments, the tape-roll sensor is configured to sense the weight (or mass) of the entire top-head assembly. In certain embodiments, the tape-roll sensor is configured to sense the outer diameter of the tape roll. In other embodiments, the tape-roll sensor is configured to sense the distance between the sensor and the outer surface of the tape roll. Regardless of the embodiment, the controller 90 is configured to use a lookup table or an algorithm to determine the resistive force that particular sensed characteristic. The controller may make this determination at any suitable point in time.

[0061] Once the top-head assembly 400 ascends above the top surface of the case C, the operator moves the case C to a holding position partially beneath the top-head assembly 400 and atop the first and second lower drive elements, at shown in Figure 6D, at which point the operator stops moving the case C. As the case C moves beneath the top-head assembly 400 and toward the holding position, the case-entry sensor S3 detects the presence of the case C beneath the top-head assembly and in response sends a corresponding case-detected signal to the controller 90. While this occurs, the controller 90 is controlling the top-head-actuating-assembly actuator(s) 395 to exert a resistive force on the top-head assembly 400 that partially counteracts the weight of the top-head assembly 400 such that the top-head assembly 400 descends, as shown in Figure 6E. Eventually, the upper drive elements of the upper drive assembly of the tophead assembly 400 engage the top surface of the case C and joins the first and second lower drive elements in moving the case C in the direction D, as shown in Figure 6F. The top-head assembly 400 exerts the target force on the case C.

[0062] The controller 90 receives a case-detected signal from the arm-retraction sensor S4 (indicating that the arm-retraction sensor S4 detected the case C) and in response controls the roller-arm actuators 1710 and the cutter-arm actuators 1810 of the lower and upper tape cartridges 1000a and 1000b to move their respective first and second roller arms 1110 and 1120 and cutter arms 1301 to their retracted positions. The leading surface of the case C contacts the front rollers 1120 as the front roller arms 1110 are moving to their retracted positions, which causes the tape positioned on the front rollers 1120 to adhere to the leading surface of the case C. When the front and rear roller arms 1110 and 1210 are in their retracted positions, the front andrear rollers 1 120 and 1220 are positioned to apply enough pressure to the tape to adhere the tape to the top and bottom surfaces of the case C. When the cutter arms 1301 are in their retracted positions, the cutter arms 1301 do not contact the top or bottom surfaces of the case C (though in certain embodiments they may do so). The controller 90 controls the roller-arm actuators 1710 and the cutter-arm actuators 1810 to retain the front and rear roller arms 1110 and 1210 and the cutter arms 1301 in their respective retracted positions as the upper and lower drive assemblies move the case C past the tape cartridges 1000a and 1000b.

[0063] The case C eventually moves off of the infeed table 112, as shown in Figure 6G, at which point the infeed-table sensor S 1 stops detecting the case C and sends a corresponding case-undetected signal to the controller 90. Responsive to receiving that case- undetected signal, the controller 90 controls the side-rail actuator 117 to move the side rails 114a and 114b from the centering configuration to the rest configuration to make space on the infeed table 112 for the next case.

[0064] At some point, the case-exit sensor S5 detects the presence of the case C (though this may occur after the arm-retraction sensor S4 stops detecting the case depending on the length of the case) and sends a corresponding case-detected signal to the controller 90.

[0065] Once the arm-retraction sensor S4 stops detecting the case C (indicating that the case C has moved past the arm-retraction sensor S4), the arm-retraction sensor S4 sends a corresponding case-undetected signal to the controller 90. In response, the controller 90 controls the roller-arm actuators 1710 of the tape cartridges 1000a and 1000b to return the first and second roller arms 1110 and 1120 to their respective extended positions to apply tape to the trailing surface of the case C and controls the cutter-arm actuators 1810 of the tape cartridges 1000a and 1000b to return the cutter arms 1301 to their extended positions to cut the tape from the rolls. As this occurs, the fingers 1344 of the cutting-device covers 1340 contact the top and bottom surfaces of the case C so the cutting-device covers 1340 pivot to their open positions and expose the cutting devices 1330. Continued movement of the cutter arms 1301 brings the toothed blades of the cutting devices 1330 into contact with the tape and severs the tape from the respective rolls R. As the front and rear roller arms 1110 and 1210 move back to their extended positions, the rear roller arms 1210 move so the rear rollers 1220 contact the severed ends of the tape and apply the tape to the trailing surface of the case C to complete the taping process.

[0066] The upper and lower drive assemblies continue to move the case C until it exits from beneath the top-head assembly 400 onto the outfeed table 113, as shown in Figure 6H, at which point the case-exit sensor S5 stops detecting the case C and sends a corresponding case- undetected signal to the controller 90. The top-head assembly 400 then descends back to its initial position, as shown in Figure 61.

[0067] Figure 7 is a flowchart of one example method 2000 of operating a case sealer of the present disclosure. The method 2000 begins by raising a top-head assembly that includes a tape cartridge supporting a tape roll, as block 2002 indicates. The method 2000 continues by sensing a characteristic associated with the tape roll, as block 2004 indicates. After a case has been positioned beneath the top-head assembly, such as by an operator, the method 2000 continues by exerting a resistive force on the top-head assembly such that the top-head assembly lowers into engagement with the case, as block 2006 indicates. The resistive force is based on the sensed characteristic. The method 2000 concludes by moving the case beneath the top-head assembly and past the tape cartridge such that tape from the tape roll is applied to the case, as block 2008 indicates.

[0068] The case sealer and method of operating the case sealer of the present disclosure solves the above problems. Specifically, by progressively lowering the resistive force as tape is used up and removed from the tape roll of the upper tape cartridge, the top-head assembly exerts a consistent target force on the case and the case sealer maintains a constant or substantially constant throughput regardless of how much tape is on the tape roll.

[0069] In some embodiments, the tape cartridge includes biasing elements that bias the roller arms and the cutter arm to their respective extended positions. The biasing elements eliminate the need for direct actuation of the roller arms and the cutter arm from their respective retracted positions to their respective extended positions.

[0070] In certain embodiments, the controller is separate from and in addition to the sensors. In other embodiments, the sensors act as their own controllers. For instance, in one embodiment, the retraction sensor is configured to directly control the cutter and roller arm actuators responsive to detecting the presence of and the absence of the case, the infeed-table sensor is configured to directly control the side rail actuator responsive to detecting the presence of and the absence of the case, and the leading-surface and top-surface sensors are configured todirectly control the top head actuator responsive to detecting the presence of and the absence of the case (or contact with the case).

[0071] In various embodiments, the controller is configured to determine the resistive force based on a speed of the top-head assembly. Specifically, the controller is configured to receive feedback from a sensor configured to monitor the speed of the top-head assembly during its descent and to compare the speed to a target speed. In these embodiments, the controller is configured to reduce the resistive force if the speed of the top-head assembly is less than the target speed (that correlates to the target force) and to increase the resistive force if the speed of the top-head assembly is greater than the target speed.

[0072] In certain embodiments, the controller is configured to determine the resistive force based on the quantity of taping cycles completed following the replacement of the tape roll. For instance, in some of these embodiments, the controller is configured to decrease the resistive force by a certain increment following each completed taping cycle.

Claims

Claims1. A case sealer comprising: a frame; a top-head assembly including a tape cartridge configured to support a tape roll; one or more top-head-assembly actuators operably connected to the top-head assembly and configured to vertically move the top-head assembly relative to the frame; and a controller configured to: control the one or more top-head-assembly actuators to raise the top-head assembly; and after a case has been positioned beneath the top-head assembly, control the one or more top-head assembly actuators to exert a resistive force on the top-head assembly such that the top-head assembly lowers into engagement with the case, wherein the resistive force is a first resistive force when the weight of the tape roll is a first weight and a second resistive force when the weight of the tape roll is a second weight, wherein the first weight is greater than the second weight, wherein the first resistive force is greater than the second resistive force.

2. The case sealer of claim 1, further comprising a sensor configured to sense a characteristic, wherein the resistive force is based on the sensed characteristic.

3. The case sealer of claim 2, wherein the controller is further configured to determine the resistive force based on the sensed characteristic.

4. The case sealer of claim 3, wherein a downward force exerted by the top-head assembly as it lowers is substantially equal to a target force regardless of the weight of the tape roll.

5. The case sealer of claim 4, wherein the controller is further configured to determine the resistive force based on a target force.

6. The case sealer of claim 2, wherein the sensed characteristic comprises a characteristic associated with the tape roll.

7. The case sealer of claim 6, wherein the sensed characteristic is indicative of a weight of the tape roll.

8. The case sealer of claim 7, wherein the sensor is configured to sense the weight of one of the tape roll and the top-head assembly.

9. The case sealer of claim 6, wherein the sensed characteristic is indicative of an outer diameter of the tape roll.

10. The case sealer of claim 9, wherein the sensor is configured to sense a distance between the sensor and an outer surface of the tape roll.

11. The case sealer of claim 6, wherein the controller is further configured to determine a weight of the top-head assembly based on the sensed characteristic and to determine the resistive force based on a difference between the weight of the top-head assembly and the target force.

12. The case sealer of claim 3, wherein the controller is configured to determine the resistive force before controlling the one or more top-head-assembly actuators to raise the tophead assembly.

13. The case sealer of claim 1, wherein a downward force exerted by the top-head assembly as it lowers is substantially equal to a target force regardless of the weight of the tape roll.

14. A method of operating a case sealer, the method comprising: raising a top-head assembly including a tape cartridge supporting a tape roll; after a case after has been positioned beneath the top-head assembly, exerting a resistive force on the top-head assembly such that the top-head assembly lowers into engagement with thecase, wherein the resistive force is a first resistive force when the weight of the tape roll is a first weight and a second resistive force when the weight of the tape roll is a second weight, wherein the first weight is greater than the second weight, wherein the first resistive force is greater than the second resistive force; and moving the case beneath the top-head assembly and past the tape cartridge such that tape from the tape roll is applied to the case.

15. The method of claim 14, further comprising sensing, via a sensor, a characteristic, wherein the resistive force is based on the characteristic.

16. The method of claim 15, further comprising determining, by a controller, the resistive force based on the sensed characteristic.

17. The method of claim 16, wherein a downward force exerted by the top-head assembly as it lowers is substantially equal to a target force regardless of the weight of the tape roll.

18. The method of claim 17, further comprising determining, by the controller, the resistive force based on the target force.

19. The method of claim 15, wherein the sensed characteristic comprises a characteristic associated with the tape roll.

20. The method of claim 14, wherein a downward force exerted by the top-head assembly as it lowers is substantially equal to a target force regardless of the weight of the tape roll.

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