Packaging improvements

Abstract

To provide a device for packing fruit or other fresh food / food in a tube.SOLUTION: An end effector adapted to be carried by a robotic positioning apparatus for packing items of produce, the end effector being used to hold an open-topped elongate container (tube) in an inverted orientation, the tube having a bottom closed end and a top open end, the end effector comprising at least one actuatable movable element disposed on the end effector so as to be adjacent the open end of the tube held by the end effector; Wherein the actuatable movable element is configured to be actuatable between an extended position in which it extends at least partially beyond the open end of the tube held by the end effector and at least partially obstructs the open end of the tube, and a retracted position in which the open end of the container is substantially unobstructed and the item of produce.SELECTED DRAWING: Figure 8

Description

[Technical Field]

[0001] (Corresponding application description) This application is based on a provisional specification filed in conjunction with New Zealand Patent Application No. 763219, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to a machine for packaging objects in tubes, in particular for packing fruit or other fresh produce / food products in tubes. [Background technology]

[0003] Apples and other fruit items are conventionally packaged in boxes. To minimize damage to the fruit, the fruit is typically supported within the box on a tray to keep the fruit separated from adjacent fruit. A single box can contain one or more layers of fruit, with each layer supported by a tray.

[0004] The applicant has introduced a novel approach to packaging fruit (apples) by packing the apples in tubes rather than trays in boxes, each tube typically containing two or more fruits, e.g., five apples.

[0005] The tube may be cylindrical or may have a square, triangular, or other cross-section. The inner dimensions of the tube correspond to the outer dimensions of the fruit so that, when full, the tube contains a single row or column of fruit. For example, in a cylindrical tube, the inner diameter of the tube is preferably slightly larger than the maximum expected diameter of the fruit. The maximum expected diameter of the fruit may be based on the known size distribution of a particular variety and / or type of fruit.

[0006] Packing fruit into tubes can lead to inefficiencies in the packing process. Each item of fruit cannot be dropped into the tube because the physical impact between the fruit as they fall into the tube can cause damage (bruising) to the fruit during packing. Also, unlike packing fruit into boxes, each item of fruit must be placed into the tube one at a time. This packing process can be time consuming and can add cost to the packing process. Summary of the Invention [Problem to be solved by the invention]

[0007] It is an object of the present invention to address one or more of the aforementioned problems, or at least to provide the public with a useful choice.

[0008] All references cited herein, including any patents or patent applications, are hereby incorporated by reference. No reference is admitted to be prior art. The description of a reference states what its author asserts, and applicants reserve the right to challenge the accuracy and pertinence of the cited documents. Although this specification refers to a number of prior art documents, it will be expressly understood that this reference is not an admission that any of these documents form part of the common general knowledge in the art in New Zealand or anywhere else. [Means for solving the problem]

[0009] According to one aspect of the present invention, there is provided an end effector adapted to be carried by a robotic positioning device for packing produce items, said end effector adapted for use in holding an open-top elongated container (tube) in an inverted orientation, said tube having a closed bottom end and an open top end, said end effector comprising: at least one actuatable movable element disposed on the end effector adjacent the open end of a tube held by the end effector; The actuatable movable element comprises: an extended position that extends at least partially beyond the open end of a tube held by the end effector and at least partially obstructs the open end of the tube; a storage position for allowing the open end of the container to be substantially unobstructed to receive an item of produce into the tube; The device is configured to be operable between

[0010] According to a second aspect of the present invention, there is provided an end effector comprising a frame for receiving a tube.

[0011] According to a third aspect of the present invention, there is provided an end effector having an actuatable movable element disposed adjacent one end of a frame.

[0012] According to a fourth aspect of the present invention, there is provided an end effector in which the actuatable movable element is made from a soft, resilient material and is resiliently deformable between a first shape in an extended position and a second shape in a retracted position.

[0013] According to a fifth aspect of the present invention, there is provided an end effector having a first shape that is circular.

[0014] According to a sixth aspect of the present invention there is provided an end effector substantially as described above, wherein the second shape is non-circular or generally elliptical.

[0015] According to a seventh aspect of the present invention there is provided an end effector substantially as described above, wherein the actuatable moveable element is substantially ring-shaped or has a substantially ring-shaped central portion.

[0016] According to an eighth aspect of the present invention, there is provided an end effector wherein the actuatable movable element comprises a first part and a second part, the first part and the second part each comprising an arcuate portion and a side member extending from each end of the arcuate portion, the first part and the second part being diametrically opposed with the side member of the first part in contact with or adjacent to the side member of the second part.

[0017] According to a ninth aspect of the present invention, there is provided an end effector in which, in a retracted position, a gap is provided between proximal or radially inner portions of the side members of the first and second parts, and in an extended position, the arcuate portions elastically deform and the proximal ends of the side members of the first and second parts move together to close the gap.

[0018] According to a tenth aspect of the present invention, a holding arrangement configured to grasp the tube and secure the tube to the end effector; A retainer is provided with an end effector that grips the tube adjacent the bottom closed end of the tube.

[0019] Preferably, the retainer modifies the cross-sectional shape of the tube to assist in frictionally securing the position of the produce within the tube during the packing operation.

[0020] According to an eleventh aspect of the present invention, there is provided an end effector, wherein the holder comprises at least one movable component movable between a disengaged position and an engaged position, wherein in the disengaged position the component does not contact the tube, and in the engaged position the component contacts the tube to compress and deform the tube.

[0021] According to a twelfth aspect of the present invention, an end effector is provided in which a robotic positioning device provides at least four degrees of freedom for moving the end effector along x-, y-, and z-axes relative to an item of produce to be packaged and for rotating the end effector about a horizontal axis between an inverted orientation and an upright orientation.

[0022] According to a thirteenth aspect of the present invention there is provided a produce packaging device comprising a controller, the controller comprising: i) controlling the positioning device to position the end effector in an inverted orientation in the x and y directions vertically above a first item of produce to be packaged and moving the end effector vertically downward to receive the first item of produce into a tube within the end effector; ii) if necessary, actuating the actuatable movable element from the retracted position to the extended position to receive the first item of fruit in the tube and, once inside the tube, actuating the actuatable movable element to the retracted position to retain the first item of fruit in the tube; iii) controlling the positioning device to move the end effector vertically upward; It is programmed to do the following.

[0023] Preferably, the positioning device is in the form of a robot.

[0024] However, the present invention contemplates employing other positioning devices capable of moving the end effector in three-dimensional space.

[0025] According to a fourteenth aspect of the present invention there is provided a produce packaging device substantially as described above, wherein the controller further comprises: iv) controlling the positioning device to move the end effector in the x and y directions to position the end effector vertically above the further item of fruit and to move the end effector vertically downward to position a next item adjacent to or in contact with the further item of fruit; v) actuating the actuatable movable element from the retracted position to the extended position; vi) controlling the positioning device to continue moving the end effector vertically downward to receive additional items of produce into the tubes within the end effector; vii) actuating the actuatable movable element from the retracted position to the extended position to retain the first item of fruit and the further item of fruit within the tube; viii) controlling the positioning device to move the end effector vertically upward; ix) repeating steps iv to viii until the tube is full; It is programmed to do the following.

[0026] According to a fifteenth aspect of the present invention there is provided a produce packaging device substantially as described above, wherein the controller further comprises: x) when the tube is full, the robotic positioning device is programmed to rotate the end effector from an inverted orientation to an upright orientation so that the open end of the tube is at the top, and move the end effector to a release area to release the tube from the end effector.

[0027] According to a sixteenth aspect of the present invention there is provided a produce packaging device substantially as described above, wherein the controller is further programmed to control the robotic positioning device to move the end effector vertically upwards and release the tube from the end effector.

[0028] According to a seventeenth aspect of the present invention there is provided a produce packaging device substantially as described above in the tenth aspect, wherein the controller further comprises: The retainer is programmed to actuate the retainer to an engaged position to grip and deform the cross-sectional shape of the tube near the closed end of the tube to prevent the first item of produce from entering the space at the closed end of the tube.

[0029] According to an eighteenth aspect of the present invention there is provided a produce packaging device substantially as described above, wherein the controller further comprises: controlling the robot positioning device to rotate the end effector from an inverted orientation to an upright orientation, position the open end of the tube at the top, and move the end effector to a release area; actuating the retainer to a disengaged position to release the tube; It is programmed to do the following.

[0030] According to a nineteenth aspect of the present invention there is provided a produce packaging device substantially as described above, the device comprising a singulation unit for spacing items of produce and presenting singulated or grouped items of produce within reach of a robotic positioning device.

[0031] According to a twentieth aspect of the present invention there is provided a produce packaging device substantially as described above, wherein the singulating unit spaces items / groups of produce in a two-dimensional array.

[0032] According to a twenty-first aspect of the present invention there is provided a produce packaging device substantially as described above, wherein the singulating unit comprises a conveyor configured to present items / groups of produce in a manner compatible with the reach of a robotic positioning device.

[0033] According to a twenty-second aspect of the present invention there is provided a produce packaging device substantially as described above, wherein in step i) the controller is programmed to control the robotic positioning device to move the end effector vertically above the item of produce and to move it in the conveying direction at the speed of the conveyor so that the end effector remains vertically above the item of produce.

[0034] According to a twenty-third aspect of the present invention there is provided a produce packaging device substantially as described above, wherein the conveyor comprises a continuous loop carrying a plurality of spaced apart holders, each holder adapted to hold a separate item of produce.

[0035] According to a twenty-fourth aspect of the present invention there is provided a produce packaging device substantially as described above, wherein the holders are spaced apart in a conveying direction and perpendicular to the conveying direction to present the produce items in a two-dimensional array.

[0036] According to a twenty-fifth aspect of the present invention there is provided a produce packaging device substantially as described above, the device further comprising a sensing device in communication with a controller to sense or detect data points for each item of produce, the controller comprising: storing in memory a data point for each item of produce associated with a respective holder of the singulating unit that holds the item of produce; controlling the robotic positioning devices and end effectors to pack each item of produce based on the data points for each item of produce; It is programmed to do the following.

[0037] According to a twenty-sixth aspect of the present invention there is provided a produce packaging device, substantially as described above, in which the holder is formed from a resilient soft material.

[0038] According to a twenty-seventh aspect of the present invention there is provided a produce packaging device substantially as described above, wherein each holder is configured as a cup with side walls extending from a base, the upper ends of the walls providing a rim for receiving an item of produce.

[0039] According to a twenty-eighth aspect of the present invention there is provided a produce packaging device substantially as described above, wherein the wall is formed to have an inner wall portion and an outer wall portion.

[0040] According to a twenty-ninth aspect of the present invention there is provided a produce packaging device substantially as described above, wherein the holder includes tabs extending radially outwardly from and spaced around the rim, and wherein an end of the end effector contacts the tabs as the end effector moves downwardly to receive an item of fruit into the tube.

[0041] According to a thirty-first aspect of the present invention there is provided a produce packaging device, substantially as described above, in which each holder is a unitary member.

[0042] According to a thirty-first aspect of the present invention there is provided a produce packaging device substantially as described above, comprising a conveying apparatus having at least one continuous loop arrangement and a plurality of spaced apart holders attached to the continuous loop arrangement, each holder adapted to support a separate item of produce, the holders being spaced apart longitudinally and laterally of the conveying apparatus such that the items of produce are discretely arranged in a two-dimensional array.

[0043] According to a thirty-second aspect of the present invention, there is provided an actuatable movable element, the actuatable movable element being made from a soft, resilient material.

[0044] According to a thirty-third aspect of the present invention there is provided an actuatable movable element, substantially as described above, the actuatable movable element being resiliently deformable between a first shape when in a retracted position and a second shape when in an extended position.

[0045] According to a thirty-fourth aspect of the present invention there is provided an actuatable movable element substantially as described above, wherein the first shape is circular.

[0046] According to a thirty-fifth aspect of the present invention there is provided an actuatable movable element substantially as described above, wherein the second shape is non-circular or generally elliptical.

[0047] According to a thirty-sixth aspect of the present invention, there is provided an actuatable movable element comprising a substantially ring-shaped central portion and having two laterally extending opposing arms arranged along a medial axis of the ring-shaped central portion.

[0048] According to a thirty-seventh aspect of the present invention, there is provided an actuatable movable element comprising a substantially ring-shaped central portion and having two laterally extending opposing arms arranged along a central axis of the ring-shaped central portion, the central ring-shaped portion being composed of two halves, each half being made along the central axis of the central ring-shaped portion, the central ring-shaped portion being perpendicular to the central axis along which the laterally extending opposing rings are arranged.

[0049] According to a thirty-eighth aspect of the present invention there is provided an actuatable movable element comprising a first part and a second part, the first part and the second part each comprising an arcuate portion and a side member extending from each end of the arcuate portion, the first part and the second part being diametrically opposed with the side member of the first part in contact with or adjacent to the side member of the second part.

[0050] According to a thirty-ninth aspect of the present invention there is provided a holder for supporting produce during transport for packaging, the holder comprising: an at least partially conical, at least partially tapered, or at least partially semicircular wall when viewed in cross section; at least one substantially horizontally outwardly projecting tab at the top rim of said conical or semicircular wall; The holder is made from a soft, resilient material.

[0051] According to a fortieth aspect of the present invention there is provided a holder substantially as described above, having six horizontally projecting tabs.

[0052] According to a forty-first aspect of the present invention there is provided a holder, substantially as described above, having an at least partly conical, at least partly tapered or at least partly semi-circular truncated wall.

[0053] According to a forty-second aspect of the present invention there is provided a holder substantially as described above, wherein a bottom of the wall is connected to a base.

[0054] According to a forty-third aspect of the present invention there is provided a holder substantially as described above, wherein the base is substantially ring-shaped when viewed from above / below.

[0055] According to a forty-fourth aspect of the present invention there is provided a holder, substantially as described above, wherein the at least partly conical, at least partly tapered or at least partly semi-circular wall is formed to have inner and outer wall portions connected by a web.

[0056] According to a forty-fifth aspect of the present invention there is provided the use of a robotic positioning apparatus (RPA) for dimensionally positioning a container to receive an article to be packaged.

[0057] Preferably, said goods are items of agricultural produce.

[0058] Preferably, the RPA also moves containers and inserts the items to be packaged therein.

[0059] Preferably, the RPA further controls an end effector to enable the item to be packaged to be placed in the container.

[0060] Preferably, the RPA also controls an end effector to hold the item to be packaged therein.

[0061] Throughout this specification the word "comprise" or variations thereof such as "comprises" or "comprising" will be understood to mean the inclusion of stated elements, integers or steps, or groups of elements, integers or steps, but not the exclusion of other elements, integers or steps, or groups of elements, integers or steps.

[0062] Further aspects and advantages of the present invention will become apparent from the following description, which is given by way of example only.

[0063] (definition) Hereinafter, the term "robot" will be understood to mean a manipulator or industrial robot having one or more joints capable of performing translational and / or rotational movements, in particular, so that one or more end effectors of the robot can have different positions (spatial locations or positions). The translational and / or rotational movements may include movement along one or more rails along which the robot's parts / arms (links) are guided. Even such rails form joints in the sense of a kinematic chain that describes the robot's movement possibilities. As used herein, the term "robot" may be understood to mean a device comprising a Cartesian robot / gantry robot, a SCARA robot / horizontal articulated robot, a cylindrical robot / cylindrical coordinate robot, a spherical robot / spherical coordinate robot, or an articulated robot. In general, as used herein, the term "robot" or "robot positioning device" may be understood to mean a device configured to move with at least four degrees of freedom, including three translational degrees of freedom and at least one rotational degree of freedom.

[0064] As used herein, the term "flexible" refers to the ability of a material to yield to physical pressure.

[0065] As used herein, the term "resilience" refers to the ability of a material to return to its original shape after being deformed by an applied force. [Brief explanation of the drawings]

[0066] Further aspects of the present invention will become apparent from the following description, given by way of example only, with reference to the accompanying drawings.

[0067] [Figure 1] 1 shows an end effector for holding a tubular container in an inverted orientation. The retaining device is configured as an end effector coupled to a robotic arm. [Figure 2] 2 shows a side view of the holding device of FIG. 1. [Figure 3] 3 shows a further side view of the end effector of FIG. 1 viewed at 90 degrees relative to the view of FIG. 2; [Figure 4] 3 shows a longitudinal cross-sectional view taken along line AA shown in FIG. 2. [Figure 5] 3 shows a cross-sectional view taken along line BB shown in FIG. 2. [Figure 6] 3 shows a cross-sectional view taken along line CC shown in FIG. 2. [Figure 7] 1 shows a robotic arm and end effector forming part of a packaging assembly. [Figure 8] 2A-2C show longitudinal and side cross-sectional views of the end effector of FIG. 1 receiving an apple into a tubular package held by a holding device. [Figure 9] 2 shows longitudinal cross-sectional and side views of the end effector of FIG. 1 holding one apple within a tubular container, with the end effector positioned above a second apple received within the tubular container held by the end effector when moved in the direction of the arrow shown. [Figure 10] 2 shows longitudinal cross-sectional and side views of the end effector of FIG. 1 holding two apples in a tubular package, with the holding device positioned above a third apple received in the tubular package held by the end effector when the end effector is moved in the direction of the arrow shown. [Figure 11]2 shows a longitudinal cross-sectional view and a side view of the end effector of FIG. 1, with a tubular package held within the holding device full of apples; [Figure 12] As shown on the left, the end effector of FIG. 1 is shown rotated as indicated by the arrow to orient the open top of the tubular package uppermost as shown on the right. [Figure 13] 2 shows a longitudinal cross-sectional view and a side view of the end effector of FIG. 1, with a full tubular package oriented with the holding device positioned on top ready to release the full package. [Figure 14] 1 shows a longitudinal section and a side view of a full tubular package when full. [Figure 15] FIG. 10 is a partially exploded view of a produce packing device or system according to a preferred embodiment of a further aspect of the present invention. [Figure 16] 16 illustrates a singulating operation performed by a singulating unit of the produce packing device of FIG. 15; [Figure 17] 16 illustrates a singulating operation performed by a singulating unit of the produce packing device of FIG. 15; [Figure 18] 16 illustrates a singulating operation performed by a singulating unit of the produce packing device of FIG. 15; [Figure 19] 16 illustrates a singulating operation performed by a singulating unit of the produce packing device of FIG. 15; [Figure 20] 16 illustrates a singulating operation performed by a singulating unit of the produce packing device of FIG. 15; [Figure 21] 16 illustrates a singulating operation performed by a singulating unit of the produce packing device of FIG. 15; [Figure 22] 10A-10C show perspective, top, side and cross-sectional views of a holder for holding individual items of produce according to a preferred embodiment of a further aspect of the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0068] (Best Mode for Carrying Out the Invention) 1-7 show an end effector 1 for holding an open-top elongated container or tube 2 in an inverted orientation for packaging items such as fruits or vegetables, including apples and tomatoes, and other items of produce (referred to herein as produce or produce items).

[0069] The end effector 1 is adapted to be mounted on the end of a robotic positioning device, as shown in FIG.

[0070] As can be seen in FIG. 7, a portion of a packing assembly 4 is shown including at least one positioning device in the form of an articulated robotic arm 3 and associated end effector 1 .

[0071] The articulated robot arm 3 can move the end effector in three-dimensional space.

[0072] 1-6, the end effector 1 includes a frame 5 for receiving a tubular container 2. The frame 5 is preferably open at both ends. In the illustrated embodiment, the frame 5 is configured as a barrel. The barrel has substantially closed longitudinal sides. The illustrated end effector 1 includes a longitudinal window 8 on one side, as shown in FIG. 2.

[0073] The frame may be configured in other ways, for example as a cage formed by a series of longitudinal members held together by one or more transverse rings.

[0074] A coupling 6 is provided on the outside of the frame 5 for attaching the end effector to a robotic positioning device. The coupling is preferably a quick release coupling, but may be any known standard coupling.

[0075] The frame 5 has a bore for receiving the tubular container 2. The bore has an inner dimension (e.g., diameter) that is slightly larger than the outer lateral dimension (diameter) of the tubular container 2. When the frame 5 is positioned vertically, as seen in Figure 2, the container 2 can also be maintained therein in an upright configuration, with the longitudinal axis AA of the container being substantially vertical (e.g., as shown in Figure 4).

[0076] As shown in FIG. 5, the fixture includes diametrically opposed movable components in the form of a pair of rams 10a actuatable via pneumatic cylinders 10 between extended and retracted positions.

[0077] In the disengaged position, the rams 10a are not in contact with the opposing sides of the tube 2. In the engaged position, the rams 10a are moved to engage the opposing sides of the tube 2, compressing them together and thereby deforming their cross-sectional shape. A retainer that deforms the cross-sectional shape of the tubular container 2 near or adjacent the closed end of the tube 2 can help frictionally secure the relative positions of the fruit within the tubular container during the packing operation as more fruit is introduced into the tube.

[0078] An alternative holder may, for example, include a single movable component 9 adapted to engage and compress the tubular container against the side of the frame opposite the movable component 9 .

[0079] The end effector 1 also has at least one actuatable movable element 7 adjacent one end of the frame. With the tubular container received in the frame, the actuatable movable element is positioned on the end effector 1 adjacent the open end of the tubular container 2.

[0080] The actuatable movable element 7 has two opposing parts 7a, 7b made from a soft elastic material (see Figure 6).

[0081] As can be seen, each part 7a, 7b has an arcuate central section with side members 7La, 7Lb extending radially outwardly from the convex side thereof.

[0082] The parts 7a, 7b are shown in an extended (open) position, diametrically opposed, with the arcuate central section forming a substantially circular (ring) shape.

[0083] This ring shape is substantially the same as or slightly larger than the circumference of the tube, so that in this extended position the end effector 1 allows the tube to receive an apple or other item of produce.

[0084] The actuatable movable element 7 and the parts 7a, 7b are The extended (open) position shown in FIG. 6; -The storage (closed) position as seen from the side in Figure 8. and is moved between them by a pneumatic cylinder 9 and an associated ram 9a.

[0085] In the extended position, the proximal ends of the side members 7La, 7Lb are moved towards each other in the direction shown by arrow Y in FIG. 6 by retracting the ram 9a.

[0086] This contraction of the ram 9a has the effect of deforming the ring shape formed by the central arcuate section of the parts 7a, 7b into an oval shape which, by its narrower dimensions, extends beyond the opening of the tube 2 and retains the apple therein.

[0087] Figures 8 and 11 show the actuatable movable element 7 in a retracted (closed) position, in which the element 7 extends at least partially beyond the end of the tube 2 to such an extent that it can retain the fruit items within the tube 2 when the inverted tube is lifted with the open top of the tube 2 facing downwards.

[0088] Thus, in the retracted position, the actuatable movable element 7 prevents produce items, such as apples, from passing through the open end of the tubular container 2 .

[0089] It should be appreciated that in some embodiments, the actuatable element 7 can move between the retracted and extended positions without deformation.

[0090] The side members of parts 7a, 7b are received in recesses in the side walls of frame 5, as shown in FIG.

[0091] Preferably, as mentioned above, the actuatable movable element 7 is formed from a soft, resilient material. For example, the actuatable movable element is formed from a polyhydroxybutyrate-co-valerate (PHBV) biopolymer such as that manufactured and sold under the trademark ENMAT by TianAn Biologic Materials Co., Ltd. This material is selected to provide a relatively soft, resilient contact with the surface of the fruit, avoiding or reducing the risk of damaging the fruit.

[0092] (Packing work) The packing operation will be described with reference to Figures 8 to 14. The packing operation is performed with the end effector 1 attached to the robot arm 3 or other robot positioning device (not shown).

[0093] The robotic positioning device 3 provides at least four degrees of freedom of movement, and is adapted to move the end effector in x, y, and z translational directions for positioning the end effector in three-dimensional space, and at least one rotational (e.g., rolling) direction that can rotate and invert the end effector about a horizontal axis. The x direction may be horizontal, the y direction may be horizontal and perpendicular to the x direction, and the z direction may be vertical.

[0094] At the start of the packing operation, the tubular container 2 is received by the end effector 1 .

[0095] For example, a robotic positioning device such as a robotic arm 3 may move the end effector 1 to a tube dispenser (not shown) to receive a tube from the top or bottom end of the frame 5 .

[0096] Alternatively, the tubular container may be inserted or placed into the frame 5 by a person.

[0097] The tubular container 2 is received in the frame 5 of the end effector 1 with the closed (bottom) end of the tubular container uppermost, i.e., the container is held by the robotic positioning device in an inverted orientation with the open top of the container facing downwards.

[0098] The robotic positioning device moves an inverted tube 2 within an end effector 1 / frame 5 in three-dimensional space to an item of produce, such as an apple A, supported on a support surface.

[0099] The robotic positioning device orients end effector 1 / frame 5, and therefore tubular container 2, vertically and positions frame 5 directly above produce item A. With the open end of tubular container 2 positioned directly above produce item A, the robotic positioning device 3 lowers end effector 1 onto produce item A to receive the produce into the open end of tubular container 2, as shown in FIG.

[0100] Upon receipt of produce item A within the tubular container 2, the actuatable movable element 7 is actuated to a retracted position to capture and retain produce item A within the tubular container 2 within the end effector.

[0101] The robotic positioning device then lifts end effector 1 to pick up the fruit from support surface S (as shown in FIG. 7) and moves end effector 1 to position it directly above a second or additional item of produce, as shown in FIG. 9.

[0102] The end effector 1 picks up the second item of produce by lowering the end effector 1 onto the second item of produce. When the end effector is lowered to the level of the second item of produce, the actuatable movable element 7 moves to an extended (closed) position to prevent the first item of produce from falling off the frame 5 of the end effector 1 when the first item of produce contacts or is adjacent to the second item of produce.

[0103] The robotic positioning device 3 continues to lower the end effector 1 until it receives the second item of produce into the tubular container 2 (see FIG. 10). As the second item of produce enters the tubular container 2, it displaces the first item of produce further into the container 2.

[0104] Upon receiving the second item of produce into the tubular container 2, the actuatable moveable member 7 is actuatable to a storage position to hold the second and first items of produce within the tubular container 2. The robotic positioning device 3 then lifts and moves the end effector 1 down to pick up the additional item of produce.

[0105] The robotic positioning device continues to pick up additional items of produce in this manner until the tubular container is full, as shown in FIG.

[0106] When the tubular container 2 is full, it will receive five apples A, as shown in FIG.

[0107] FIG. 11 shows the actuatable movable element 7 in a retracted position to retain the bottom apple, and therefore all of the apples, within the tubular container 2.

[0108] Next, the robotic positioning device 3 with the end effector 1 lifts the last item of produce from the support surface S, and the robotic positioning device 3 rotates the end effector 1 as shown by the arrow in FIG. 12 to position the open top of the tubular container at the top, as shown in FIG. 13.

[0109] Preferably, the end effector 1 has a holder configured to grip an inverted tubular container as described above.

[0110] During the process, the holder 10 continues to deform the cross-sectional shape of the tubular container 2 near the closed end of the tubular container 2. This helps ensure that items of produce A do not substantially fall or move along the tubular container 2 into the space at the end of the container. The tubular container stands upright when rotated from an inverted orientation with the open top facing down to an upright orientation with the open top facing up.

[0111] The holding fixture, via the pneumatic cylinder 10 and ram 10a, slightly pinches the tubular container 2 so that the produce item A is substantially held between the holding fixture 10 and the actuatable movable element 9. During rotation, the pinching Preventing / restricting the topmost item of produce in the tube from entering the space at the closed end of the tube to prevent potential damage to said item of produce, i.e., preventing the risk of damage / bruising to the item of produce when rotating the end effector from an inverted to an upright orientation. Useful.

[0112] Furthermore, this clamping prevents the produce from rotating or moving along the tubular package as the end effector is rotated, causing it to become misaligned within the tubular container, i.e., maintaining the desired orientation of the produce items.

[0113] For example, produce items such as apples may be presented on a surface against the end effector with the fruit stem-down. The holder 10 ensures that the fruit is presented stem-up within the tubular container. Other orientations, such as presenting the fruit with the red side facing the display window of the tubular container, may be desirable.

[0114] The robot positioning device 3 moves the end effector 1 to the release area and releases the tubular container from the end effector.

[0115] Once the tube container 2 is properly oriented, the retainer 10 is actuated into a disengaged position, releasing the tube 2 from its clamped configuration and allowing the produce to controllably fall and deposit into the closed bottom of the tube container 2.

[0116] The robotic positioning device 3 then lifts the end effector 1 off the tubular container 2 as a result of disengaging the holder 10, as indicated by the arrow shown in FIG.

[0117] Figure 14 shows the tubular container 2 full of apples. To complete the packing operation, the open top of the container can be capped.

[0118] Those skilled in the art will appreciate that a controller (e.g., a programmable logic controller (PLC)) is provided to control the movement of the robot positioning device 3 and the actuation of the rams 9a, 10a. Control lines are provided from a power source to the actuators 9, 10, controlled, for example, by control valves, pneumatic lines from a pressurized air supply which are in turn controlled by the controller.

[0119] The controller may be internal or external to the robotic positioning device.

[0120] Figure 15 provides a partial exploded view of a produce packing device or system 100. The produce packing device comprises at least one robotic positioning device 3, an end effector 1 (not shown in Figure 15), and a singulating unit 101 for singulating produce fed to the produce packing device 4, as described above.

[0121] The singulating unit 101 separates the produce (not shown) to space the produce at least in lines or rows.

[0122] In the illustrated embodiment, the singulating unit separates the produce so that the produce is spaced two-dimensionally, i.e., in a two-dimensional array. The produce items are spaced in the x and y directions (as indicated by the openings 150 in the conveyor belt 151).

[0123] The singulated produce is presented within the reach (area) of each of at least one robotic positioning device 3 having an end effector 1 so that the produce can be packed into tubular packages held by the end effector 1 as described above.

[0124] The produce is spaced far enough apart on the conveying surface so that the end effector 1 can be lowered onto individual items of produce without contacting adjacent items of produce.

[0125] Figures 15 to 22 illustrate the singulating operation performed by singulating unit 101. As shown in Figure 16, produce (apples in the illustrated example) is provided to the singulating unit from an infeed conveyor 102.

[0126] An infeed conveyor 102 conveys the produce toward a lane barrier 103 to separate the produce into at least one row or lane, and preferably into multiple adjacent lanes as shown.

[0127] The in-feed conveyor 102 may comprise one or more conveying devices for moving the produce in a conveying direction. In the illustrated embodiment, the in-feed conveyor is a conveyor belt.

[0128] The produce continues to be transported on the infeed conveyor 102 along lanes soon defined by lane dividers 103 towards a separation device 104 (comprising lane dividers 103 and movable stop blocks 105) (Figure 17) which separates the produce items in the longitudinal or conveying direction (y-direction) of the singulating unit 101.

[0129] The produce items continue along the lanes defined by lane dividers 103 until they reach a stop block 105, as shown in FIG.

[0130] When an item of produce contacts or is adjacent to stop block 105, stop block 105 is lowered to receive the item of produce on its upper surface, as shown in FIG.

[0131] The stop block then rises to lift the produce item onto ramp surface 106 downstream of stop block 105, as shown in FIG.

[0132] The upper surface of the stop block 105 slopes downwardly toward the downstream ramp surface 106 so that when in the raised position, individual items of produce move down the stop block and ramp surface and are received onto holding components or holders 108, as shown in Figures 20 and 21.

[0133] In the illustrated embodiment, the separation device includes a stop flap 107 that contacts the item of produce as it travels across the ramp surface 106 to receive the item of produce into a holder 108 in a controlled manner.

[0134] The flaps 108 remain in a rest or initial position before contacting the item of produce, as shown, for example, in Figure 19. As the item of produce moves down the ramp surface 106, the produce contacts the flaps 107, moving them away from the rest or initial position to allow the produce to continue moving down the ramp and onto the holders 108, as shown in Figures 20 and 21. The flaps may be flexible and may be movably mounted, for example, on a pivot. Preferably, the flaps are biased to the rest or initial position and provide a light contact with the produce to prevent damage to the produce. Other arrangements may be provided for separating or singulating the produce into one or more spaced columns or rows.

[0135] In the illustrated embodiment, the singulating unit 101 further comprises a singulating conveyor 109. The singulating conveyor comprises a continuous conveyor loop or belt 110 (see FIG. 21) that carries the holders 108.

[0136] The holders 108 are spaced apart in the conveying direction along the conveyor belt 110. In the illustrated embodiment, the singulated conveyor comprises holders 108 spaced apart in the conveying direction along the conveyor belt 110 and spaced apart in two dimensions across the conveyor belt and perpendicular to the conveying direction to present produce items to the robotic positioning devices and end effectors in a two-dimensional array.

[0137] Each holder holds a single individual item of produce and represents a location on the conveyor (or in a two-dimensional array). Although only a few holders 108 are shown in Figure 21, one skilled in the art will understand that the illustrated singulating conveyor has many holders located at locations identified in Figure 15 by holes in the singulating conveyor.

[0138] Once the produce items are received into their respective holders, the produce is singulated and ready to be picked up by the robotic positioning device 3 for receipt into tubes carried by the end effector 1 as described above.

[0139] The produce is spaced far enough apart so that the end effector 1 can be lowered onto individual items of produce without contacting adjacent items of produce.

[0140] The robotic positioning device 3 is controlled to position the end effector 1 in an inverted position vertically above the item of produce and move in the conveying direction (y) at the speed of the conveyor so that the end effector 1 remains vertically above the item of produce as the robotic positioning device 3 moves the end effector 1 vertically downward over the item of produce to receive the produce into the end effector 1.

[0141] Once received into the end effector 1, the robotic positioning device 3 lifts the fruit item from the holder 108 while still moving in the conveying direction at the speed of the conveyor 109. Once received into the end effector and lifted from the holder, the robotic positioning device 3 is controlled to move to position the end effector 1 over the next item of produce to be packaged, repeating the downward and then upward vertical movement while simultaneously moving in the conveying direction.

[0142] In a packing operation, produce items may not be packed before they reach the end of the singulating conveyor 109. Produce items that reach the end of the conveyor may be collected and returned to the infeed conveyor 102 to be re-singulated for packing. Produce items may also be collected, for example by a person, into containers and returned to the infeed conveyor.

[0143] 22 shows one embodiment of the holder 108. The holder 108 is formed from a soft, resilient material so that the produce item can be received on the holder 108 without damaging it. The resilient material may be silicone rubber or other suitable resilient material. The holder may be a one-piece member (single part), such as, for example, a one-piece molded member.

[0144] The holder 108 is configured as a cup providing an upper rim 120 upon which a single item of produce rests. In the illustrated embodiment, the cup includes side walls 121 extending from a base 122, the upper ends of which provide the rim 120 for receiving the item of produce. The item of produce may contact the inner surface on the upper region of the rim or wall 121. The base 122 is attached to the continuous conveyor 110.

[0145] In the illustrated embodiment, the wall 121 is conical, although other shapes, such as cylindrical, are possible. The wall 121 is wall-formed to have an inner wall portion 123 and an outer wall portion 124. This configuration provides a web 125 between the inner and outer wall portions, and thus a longer wall for a given produce size helps provide a soft, resilient cushion for receiving the produce item. The illustrated embodiment also has a tab 126 extending radially outward from the rim 120. The tab 126 also helps provide a soft, resilient cushion for receiving the produce item.

[0146] The holder 108 also has an outwardly projecting circumferential flange 127 where the wall 121 and base 122 intersect, which helps to support the produce within the holder.

[0147] 8 and 11, when the end effector 1 moves downward to receive an item of produce in a tube, the end of the end effector 1 contacts the tab 126. This contact may define the height to which the actuatable element 7 is moved to the retracted position.

[0148] The holder 108 is configured so that the item of produce rests high enough on the holder 108 to receive the item of produce into the end effector 1 at the widest perimeter of the item below the actuatable element 7, such that when the actuatable element 7 is moved to the retracted (closed) position, the item of produce is captured within the tube 2 above the actuatable element 7.

[0149] As mentioned above, the holders 108 are made of a resilient, soft material to protect the produce from being bruised or otherwise damaged during the packaging operation.

[0150] Preferably, the holder 108 may be made from polyhydroxybutyrate-co-valerate (PHBV) biopolymer, such as that manufactured and sold under the trademark ENMAT by TianAn Biologic Materials Co., Ltd. PHBV biopolymer is biobased and biodegradable.

[0151] The packaging device 100 includes a sensor device 111 (FIG. 15) for sensing or detecting each item of produce in the singulated items of produce. The device 100 also includes a controller having a memory in communication with the sensor device, the controller configured to store in the memory a data point for each item of produce associated with a respective holder 108 holding the item of produce.

[0152] In a preferred embodiment, the singulating unit 101 presents the produce items in a two-dimensional array, and the controller stores in memory a data point for each location in the two-dimensional array. Each location may be represented by an x,y coordinate, which may be tracked or updated by the controller as the conveyor moves the singulated produce in a conveying direction.

[0153] The robotic positioning device 3 moves the end effector 1 so that it is overhead the holder 108 and collects the produce item based on the data points of the produce item associated with the holder.

[0154] The data point may be a binary indicator of whether or not an item of produce is present on the holder 108. If the data point indicates that an item of produce is present, the controller controls the robotic positioning device 3 to move the end effector 1 to the holder 108 to pick up the item of produce.

[0155] The present invention may also be broadly stated as consisting of any or all of the parts, elements and features referred to or indicated in the specification of this application, individually or collectively, in any combination of two or more of said parts, elements or features.

[0156] Aspects of the present invention have been described by way of example only and it will be appreciated that modifications and additions can be made without departing from the scope thereof as defined in the appended claims.

Claims

1. 1. An end effector adapted to be carried by a robotic positioning device for packing produce items, the end effector adapted for use in holding an open-top elongated container (tube) in an inverted orientation, the tube having a closed bottom end and an open top end, the end effector comprising: at least one actuatable movable element disposed on the end effector adjacent the open end of a tube held by the end effector; The actuatable movable element comprises: an extended position that extends at least partially beyond the open end of a tube held by the end effector and at least partially obstructs the open end of the tube; a storage position for allowing the open end of the container to be substantially unobstructed and an item of produce to be received within the tube; The end effector is configured to be operable between.

2. The end effector of claim 1 , wherein the end effector comprises a frame for receiving the tube.

3. The end effector of claim 2 , wherein the actuatable movable element is disposed adjacent one end of the frame.

4. 4. The end effector of claim 1, wherein the actuatable movable element is made from a soft, resilient material and is resiliently deformable between a first shape when in the extended position and a second shape when in the retracted position.

5. The end effector of claim 6 , wherein the first shape is circular.

6. The end effector of claim 4 or 5, wherein the second shape is non-circular or generally elliptical.

7. The end effector of any one of claims 1 to 6, wherein the actuatable movable element is substantially ring-shaped or has a substantially ring-shaped central portion.

8. 8. The end effector of claim 7, wherein the actuatable movable element comprises a first part and a second part, the first part and the second part each comprising an arcuate portion and a side member extending from each end of the arcuate portion, the first part and the second part being diametrically opposed with the side member of the first part contacting or adjacent the side member of the second part.

9. 9. The end effector of claim 8, wherein in the retracted position a gap is provided between proximal or radially inner portions of the side members of the first and second parts, and in the extended position the arcuate portions elastically deform and proximal ends of the side members of the first and second parts move together to close the gap.

10. The end effector a retainer configured to grasp the tube and secure the tube to the end effector; The end effector of any one of claims 1 to 9, wherein the retainer grips the tube adjacent the bottom closed end of the tube.

11. 11. The end effector of claim 10, wherein the retainer comprises at least one movable component movable between a disengaged position and an engaged position, wherein in the disengaged position the component does not contact the tube and in the engaged position the movable component contacts the tube to compress and deform the tube.

12. 12. A produce packing device comprising a robotic positioning apparatus and an end effector according to any one of claims 1 to 11, wherein the robotic positioning apparatus provides at least four degrees of freedom for moving the end effector along x, y and z axes relative to an item of produce to be packaged and for rotating the end effector about a horizontal axis between inverted and upright orientations.

13. i) controlling the robotic positioning device to position the end effector in an inverted orientation in x and y directions vertically above a first item of produce to be packaged and to move the end effector vertically downward to receive the first item of produce into the tube within the end effector; ii) if necessary, actuating said actuatable movable element from said retracted position to said extended position to receive said first item of fruit in said tube, and once inside said tube actuating said actuatable movable element to said retracted position to retain said first item of fruit in said tube; iii) controlling the robotic positioning device to move the end effector vertically upward; and 13. The device of claim 12, comprising a controller programmed to:

14. The controller further comprises: iv) controlling the robotic positioning device to move the end effector in the x and y directions to position the end effector vertically above a further item of fruit and to move the end effector vertically downward to position a next item adjacent to or contacting the further item of fruit; v) actuating the actuatable movable element from the retracted position to the extended position; vi) controlling the positioning device to continue moving the end effector vertically downward to receive the additional item of produce in the tube within the end effector; vii) actuating the actuatable movable element from the retracted position to the extended position to retain the first item of fruit and the further item of fruit within the tube; viii) controlling the robotic positioning device to move the end effector vertically upward; and ix) repeating steps iv to viii until the tube is full; 14. The device of claim 13, programmed to:

15. The controller further comprises: x) when the tube is full, control the robotic positioning device to rotate the end effector from the inverted orientation to an upright orientation so that the open end of the tube is at the top, and move the end effector to a release area to release the tube from the end effector.

16. 16. The device of claim 15, wherein the controller is further programmed to control the robotic positioning device to move the end effector vertically upward and release the tube from the end effector.

17. When dependent on claim 10, the controller further comprises: actuating the retainer to an engaged position to grip and deform the cross-sectional shape of the tube near the closed end of the tube to prevent the first item of produce from entering the space at the closed end of the tube; A device according to any one of claims 13 to 16, which is programmed.

18. The controller further comprises: controlling the robot positioning device to rotate the end effector from the inverted orientation to an upright orientation, position the open end of the tube at an uppermost position, and move the end effector to a release area; actuating the retainer to a disengaged position to release the tube; 20. The device of claim 17, programmed to:

19. 19. The device of any one of claims 13 to 18, wherein the device comprises a singulating unit for spacing the items of produce and presenting singulated or grouped items of produce within reach of the robotic positioning device.

20. 20. The device of claim 19, wherein the singulating unit spaces the items / groups of produce in a two-dimensional array.

21. 21. A device according to claim 19 or 20, wherein the singulating unit comprises a conveyor configured to present the items / groups of produce in a manner compatible with the reach of the robotic positioning device.

22. 22. The device of claim 21, wherein in step i), the controller is programmed to control the robotic positioning device to move the end effector vertically above an item of produce and in a conveying direction at a speed of the conveyor so that the end effector remains vertically above the item of produce.

23. 23. The device of claim 21 or 22, wherein the conveyor comprises a continuous loop carrying a plurality of spaced apart holders, each holder adapted to hold a separate item of produce.

24. 24. The device of claim 23, wherein the holders are spaced apart in a conveying direction and perpendicular to the conveying direction to present the items of produce in a two-dimensional array.

25. the device further comprising a sensing device in communication with the controller for sensing or detecting a data point for each item of produce, the controller comprising: storing in a memory a data point for each item of produce associated with a respective holder of said singulating unit that holds said item of produce; controlling the robotic positioning device and the end effector to pack each item of produce based on the data points for each item of produce; 25. A device according to claim 23 or 24, programmed to:

26. A device according to any one of claims 23 to 25, wherein the holder is formed from a soft, resilient material.

27. A device according to any one of claims 23 to 26, wherein each holder is configured as a cup with side walls extending from a base, the upper ends of said walls providing a rim for receiving an item of produce.

28. 28. The device of claim 27, wherein the wall is walled to have an inner wall portion and an outer wall portion.

29. 29. The device of claim 27 or 28, wherein the holder includes tabs extending radially outward from and spaced around the rim, and wherein an end of the end effector contacts the tabs when the end effector moves downward to receive a fruit item into the tube.

30. A device according to any one of claims 23 to 28, wherein each holder is a one-piece member.

31. 1. A produce packing device for packing items of produce, the device comprising a conveyor having at least one continuous loop arrangement and a plurality of spaced apart holders attached to the continuous loop arrangement, each holder adapted to support a separate item of produce, the holders being spaced apart longitudinally and laterally of the conveyor such that the items of produce are discretely arranged in a two-dimensional array.

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