Head unit for a robotic labeler and related systems and methods

Abstract

A robotic labeling system may be configured for providing one or more labels to an object. The labeling system may include a single robot configured so as to retrieve at least one label from any of a plurality7 of label printers. The robot may include a head unit that is configured to facilitate the retrieval of any of various different labels and to selectively apply labels to objects.

Description

HEAD UNIT FOR A ROBOTIC LABELER AND RELATED SYSTEMS ANDMETHODSCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to US Provisional Patent Application No. 63 / 548.350 titled, “Robotic Labeling System"’ filed November 13, 2023. The foregoing application is fully incorporated herein by reference.FIELD

[0002] This disclosure generally relates to a head unit for a robotic labeler and to related robotics systems and methods for placing a label on an object.BACKGROUND

[0003] This section is intended to provide a background or context to the invention that is recited in the claims. The description herein may include concepts that could be pursued but are not necessarily ones that have been previously conceived or pursued. Therefore, unless otherwise indicated herein, what is described in this section is not prior art to the description and claims in this application and is not admitted to be prior art by inclusion in this section.

[0004] Generally, labeling systems and machines exist which may be capable of providing a label to a package or box one label at a time. These labeling systems may, for example, include labeling machines dedicated to adding a given label at a certain position on a package. However, existing labeling machines may lack the flexibility to grab different labels using a single robotic labeler and may not be configured for labeling packages or boxes that may be of different sizes or oriented in different positions (e.g.. rotated or turned on a conveyer). Accordingly, for some labeling operations, including, for example, operations that may require the application of a plurality of different labels more than one labeling system or labeling station may be required generally adding to the overall cost and complexity of labeling systems and methods.

[0005] In light of these and other deficiencies, it would be advantageous to provide a flexible robotic labeling system that may allow such operations to be done using a single dedicated machine or labeling station. Generally, to accomplish this objective a head unit of a robotic labeler may be configured to retrieve different types of labels (e.g., different sizes and styles of labels) and to position and apply labels of each type with high efficiency, accuracy.and speed. Some embodiments herein are directed to a customized head unit for a robotic labeler. In some embodiments, the head units described herein may be configured for coupling with a specialized label printer tray configured to guide a label into a supported position for engagement with the head. This may, for example, involve use of a fan operatively coupled to a tray unit. Using head units and label printers as described herein any of various different sizes and / or styles of labels may be printed and applied to packages without demanding different robotic units or heads, for example.

[0006] Generally, systems as described herein may be configured for flexible labeling of packages or other objects. For example, systems as described herein may be configured to apply one or more labels to boxes with different sizes and apply different labels in two or more different predetermined positions on a box. Notably, this may be accomplished even if the box is received on a conveyor rotated or turned in different directions. Systems herein may, for example, put one or more labels on the top of a package or box, on the side of a package or box, on the front of a package or box, or on any combination of the aforementioned sides.

[0007] While the capability for flexible positioning and placement of labels is beneficial for a number of reasons, this presents challenges when configuring methods for label verification. For example, a single labeling line may be configured to label packages, including, for example, multi-package orders along a common feed line so that different packages and label combinations may need to be applied and checked. Some systems in the prior art may use barcode readers to verify or check to make sure a proper label has been applied to a given package. This may, for example, require placement of a plurality of barcode readers at each of a plurality of positions so that barcodes on labels in different positions may be scanned. However, such operations may add to the overall footprint of a labeling line and add cost and complexity to the system. In some embodiments, head units as described herein may include a head unit including a barcode reader. The head units may be configured to apply a label to a package and to read a barcode included on the label in an integrated process when applying the label to the package. Embodiments in which a barcode reader is integrated into a head unit of a pick and place robot and configured for control as described above may provide significant cost and time savings in labeling systems and methods.

[0008] More generally, the systems herein may be integrated into different protocols for checking for errors in labeling, providing for substantial improvements in time and cost as compared to other systems in the prior art. For example, in some embodiments, systems herein may include an image or shape detection system configured for identification of one or more physical properties of a package. For example, an image or detection system may determinephysical properties of a package including its size and shape. In some embodiments, physical properties of a package may be determined and used for selective identification of different boxes in a multi -package order or otherwise integrated in an error checking methodology. In some embodiments, an image or shape detection system may be integrated together with other sensors on a robotic head unit.

[0009] There is a need for improved systems and methods for applying labels, including, for example, systems and methods that may provide for addition of labels in a predetermined or customer desired position and orientation. The improved head units and label printers as described herein may help to advance robotic systems that facilitate flexible and low cost methods for applying labels. Furthermore, the improved head units and label printers described herein may be used to reduce errors and virtually eliminate the need for manual error checking of packages.SUMMARY

[0010] It is an objective of some embodiments herein to provide systems and methods that provide for labeling of obj ects, such as packages or boxes, over topography or that may compensate for damaged or irregularly shaped boxes. Some such embodiments, may, for example, help to facilitate more flexible systems and methods for labeling boxes including those wherein an end user may specify a preferred location for labeling a package or box or where the system itself may determine an ideal position for adding a label. In some embodiments, a robot labeling head may facilitate the above objectives or other objectives as described herein.

[0011] In some embodiments, a robot labeling head may include a housing configured for mounting to a multi-axis robotic arm; a pick plate coupled to the housing so as to form a first side thereof, the pick plate including one or mor reliefs configured for receiving one or more rails of a tray for a label printer, the tray being configured for holding a label dispensed from the label printer; the pick plate being coupled to the housing so as to form a side thereof, the pick plate forming a pl ural ity of apertures through which air may pass into the housing, the pick plate coupled so as to permit movement of the pick plate with respect to the housing when the pick plate is pressed against an object; and a fan enclosed by the housing and disposed so as to draw air into the housing through the plurality of apertures.

[0012] It is an objective of some embodiments herein to provide systems and methods that provide for labeling of objects, such as packages or boxes, using different labels such as may be formed in different sizes or styles. In some embodiments, a robot labeling head mayfacilitate the above objectives or other objectives as described herein.

[0013] In some embodiments, a robot labeling head may include a housing configured for mounting to a multi-axis robotic arm; a pick plate coupled to the housing so as to form a first side thereof, the pick plate including one or mor reliefs configured for receiving one or more rails of a tray for a label printer, the tray being configured for holding a label dispensed from the label printer; the pick plate being coupled to the housing so as to form a side thereof, the pick plate forming a plurality of apertures through which air may pass into the housing, the pick plate coupled so as to permit movement of the pick plate with respect to the housing when the pick plate is pressed against an object. The robot labeling head may further include a fan enclosed by the housing and disposed so as to draw air into the housing through the plurality of apertures; and a damper translatably coupled to the first side, the damper being adjustable between a closed position in which the damper substantially prevents air from being drawn into the housing through the plurality of apertures and an open position in which air flow may flow through the plurality of apertures.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Fig. 1 is a perspective side view of an embodiment of a robotic object labeling system.

[0015] Fig. 2 is a side elevation view of the robotic object labeling system of Fig. 1.

[0016] Fig. 3 is a perspective side view of a package with a label applied thereto.

[0017] Fig. 4A is a perspective side view of the package of Fig. 3 showing a first orientation of the package as may be the case prior to applying a label.

[0018] Fig. 4B is a perspective side view of the package of Fig. 3 showing a second orientation of the package as may be the case prior to applying a label.

[0019] Fig. 5 is a perspective side view of the package of Fig. 3 showing each of a first and a second label applied thereto.

[0020] Fig. 6 is a perspective side view of the package of Fig. 3 showing each of a first and a second label applied thereto and showing coordinate axes for positioning the first label in a target position on a front face of the package.

[0021] Fig. 7 is a perspective view of an opened box showing a label applied thereto. A flyer or pamphlet is shown dropped into the box.

[0022] Fig. 8 is a schematic diagram of an embodiment of a communications and processing system.

[0023] Fig. 9 is a perspective view of a part of an object labeling system showing aplurality of label printers and with a head unit of a robot positioned for retrieval of a label from one of the plurality of label printers.

[0024] Fig. 10 is another perspective view of a part of an object labeling system. InFig. 10, the head unit of the robot is shown positioned for labeling a package.

[0025] Fig. 11 is a perspective view of an embodiment of a head unit for a robot.

[0026] Fig. 12 is another perspective view of the head unit of Fig. 11.

[0027] Fig. 13 is a bottom plan view of the head unit of Fig. 11.

[0028] Fig. 14 is an exploded view of the head unit of Fig. 11 .

[0029] Fig. 15 is a side elevational view of the head unit of Fig. 11 showing the cross section line E-E.

[0030] Fig. 16 is a cross sectional view of the head unit of Fig. 15 taken along the cross section line E-E of Fig. 15.

[0031] Fig. 17 is another side elevational view of the head unit of Fig. 11 showing the cross section line A-A and with a plate of the head unit in an extended configuration.

[0032] Fig. 18 is a cross sectional view of the head unit of Fig. 17 taken along the cross section line A-A and showing the plate of the head unit in an extended configuration.

[0033] Fig. 19 is another side elevational view of the head unit of Fig. 11 showing the cross section line B-B and with a plate of the head unit in a compressed configuration.

[0034] Fig. 20 is a cross sectional view of the head unit of Fig. 19 taken along the cross section line B-B and showing the plate of the head unit in a compressed configuration.

[0035] Fig. 21 is a perspective view of a label printer mounted in a cartridge and showing the boundary of detailed region C.

[0036] Fig. 22 is a perspective view of the label printer of Fig. 21 showing the detailed region C.

[0037] Fig. 23 is a side elevational view of the label printer of Fig. 21 showing the boundary of detailed region D.

[0038] Fig. 24 is a side elevational view of the detailed region D.

[0039] Fig. 25 is a perspective view of a label printer and ahead unit of a robotic labeler in a first position in a method for retrieving labels.

[0040] Fig. 26 is a perspective view of a label printer and a head unit of a robotic labeler in a second position in a method for retrieving labels.

[0041] Fig. 27 is a perspective view' of a label printer and ahead unit of a robotic labeler in a third position in a method for retrieving labels.

[0042] Fig. 28 is a side elevation view of a label printer and a head unit of a roboticlabeler in a first position in a method for retrieving labels.

[0043] Fig. 29 is a side elevation view of a label printer and a head unit of a robotic labeler in a second position in a method for retrieving labels.

[0044] Fig. 30 is a side elevation view of a label printer and a head unit of a robotic labeler in a third position in a method for retrieving labels.

[0045] Fig. 31 is a perspective view of the label printer and cartridge of Fig. 21. In Fig. 31 a wall of the cartridge has been removed so as to reveal an internal rail system disposed within the cartridge.

[0046] Fig. 32 shows an embodiment of a label including a removable backing.

[0047] Fig. 33 is a side view of another embodiment of a head unit for a robotic labeler.

[0048] Fig. 34 is a bottom plan view of the head unit of Fig. 33 shown with an internal damper in an open position so that suction may be provided through all regions of the head unit.

[0049] Fig. 35 is another bottom plan view of the head unit of Fig. 33 shown with a damper in a closed position so as to limit suction to one side or region of the head unit.

[0050] Fig. 36 is a perspective view of another embodiment of a head unit for a robotic labeler. In Fig. 36 a portion of an outer plate has been removed so as to show internal dampers as included therein and positioned so as to block flow of air to internal fans disposed in the head unit housing.

[0051] Fig. 37 is another perspective view of the head unit of Fig. 36. In Fig. 37 a portion of an outer plate has been removed so as to show internal dampers as included therein and positioned so as to allow' air flow to internal fans disposed in the head unit housing.

[0052] Fig. 38 shows another view of the head unit of Fig. 36 and showing cross section line A-A.

[0053] Fig. 39 shows a cross section view' of the head unit of Fig. 38 taken along the line A-A and with the head unit in a closed configuration with dampers preventing air flow to internal fans disposed in the head unit housing.

[0054] Fig. 40 shows another view of the head unit of Fig. 36 and showing cross section line B-B.

[0055] Fig. 41 shows a cross section view' of the head unit of Fig. 40 taken along the line B-B and with the head unit in an open configuration with dampers allowing air flow to internal fans disposed in the head unit housing.

[0056] Fig. 42 is a perspective view of another embodiment of a head unit.

[0057] Fig. 43 is another perspective view of the head unit of Fig. 39 shown so as tobeter orient the botom side of the head unit for viewing.

[0058] Fig. 44 is a side elevational view of an embodiment of a plunger assembly showing the cross section line H-H.

[0059] Fig. 45 is a cross sectional view of the plunger assembly of Fig. 41 taken along the line H-H of Fig. 41.

[0060] Fig. 46 is another side elevational view of a plunger assembly and showing a pressure sensor positioned thereon.

[0061] Fig. 47 shows one example of an object with a curved side and showing how a robotic labeler with a head unit including a plurality of plungers may conform to the surface of the object when applying a label thereto.

[0062] Fig. 48 shows another example of an object that may be labeled using robotic labelers as described in some embodiments herein.

[0063] Fig. 49 is a flow chart showing an embodiment of a method for applying a label to an object.

[0064] Fig. 50 is a flow chart showing an embodiment of a method for error checking labels.

[0065] Fig. 51 is a cross sectional view of a plunger assembly similar to that shown in Fig. 44 but including adjacent structure adjacent to the plunger assembly.DETAILED DESCRIPTION

[0066] As used herein, the following terms should be understood to have the indicated meanings:

[0067] When an item is introduced by “a” or “an,” it should be understood to mean one or more of that item.

[0068] “Comprises” means includes but is not limited to.

[0069] “Comprising” means including but not limited to.

[0070] “Having” means including but not limited to.

[0071] This disclosure is generally directed to systems for labeling objects and to related system components and methods. For example, some embodiments described herein are directed to a head unit for a robot labeling device. Other embodiments may be directed to robotic systems including a robotic head unit, label printers and other systems and methods. Generally, objects to which labels may be applied in the systems and methods described herein include packages such as may be labeled with a shipping label for delivery'. However, in someembodiments, the systems and methods described herein may be configured differently and may be configured for labeling other types of objects. Generally, in this disclosure, any of objects, packages, boxes, letters, containers, items, tubes, or other things may sometimes be referred to as receiving labels. However, unless the context indicates otherwise, such description should not be taken as limiting. The systems and methods described herein may include or make use of a robot such as may include a head configured for retrieving a label and for positioning and orienting the label for placement on an object. Robots as described herein may, for example, be multi-axis pick-and-place robots such as may be configured to selectively retrieve a label from one or more printers, hold the label when positioning the label for placement, and place the label on an object in a desired position, orientation, or both.

[0072] As described above, some embodiments herein may be directed towards a head unit for a robotic labeler and to label printers that may be configured for use with such head units. As context forthose embodiments, an overview of an overall system for applying labels is first provided.SYSTEMS FOR APPLYING LABELS USING A ROBOTIC LABELER

[0073] In some embodiments, a robot may include a head coupled to an adjustable arm. The adjustable arm may be configured for movement in a plurality of directions (e.g., movement along any of an x-axis, ay-axis, and a z-axis) and may be controlled so as to position the robot’s head for retrieving labels from at least one of several different label printers. For example, Fig. 1 and Fig. 2 show an embodiment of a robotic object labeling system 10 including a robot 20 including an adjustable arm. The robotic object labeling system 10 may be configured to selectively retrieve labels from any of three different label printers 16A, 16B, 16C and apply the labels on objects in a preselected position and / or orientation. In some embodiments, object labeling system 10 may be configured to automatically select a best option for labeling an object such as may be automatically applied if specifications for either or both of a position and orientation for applying a label is not provided.

[0074] As shown in Fig. 1, the robotic object labeling system 10 may comprise, among other things, an object entry portal 12, labeling components 18 (e.g., a robot 20 for retrieving labels from any of the label printers 16A, 16B, 16C), and an object exit portal 14. A conveyor belt system or other suitable system may be used for movement of objects between the object entry portal 12 and the object exit portal 14 and for movement of an object in position forengagement with labeling components 18 of the system. In some embodiment, additional components of the labeling system 10 including, for example, an imaging or shape identification system 62 and a communication and processing system 40 may work together with the robot 20 and printers 16 A, 16B, 16C to control system operations involving retrieval and application of printed labels. The object labeling system 10 may further include one or more data input devices as may be configured for inputting data, including, for example, specification data indicating requirements for the position and / or orientation of an applied label. For example, this data may be provided to the processing system 40 using an input device embodied as a computing device, smartphone, or other communicative device. A frame 22 may generally form the body of robotic labeling system 10 and provides structure upon which other components of the system may be mounted. For example, in the embodiment shown in Fig. 1, frame 22 may provide structure (e.g., a pair of horizontal support members 54, 56) upon which cartridges or trays 110A, HOB, 110C may be mounted. The label printers 16A, 16B, and 16C may then be secured, respectively, to the cartridges or trays 110A, HOB, 110C using an internal rail system or other mount, for example.

[0075] Generally, the labeling system 10 may receive objects in the form of packages in a variety of shapes, such as boxes, tubes, envelopes, and round packages, through the entry portal 12. In some embodiments, the labeling system 10 may receive objects in any of a plurality of different positions and orientations yet still maintain the ability to properly place a label in a desired position and / or orientation on the object. For example, as shown in Fig. 3, labeling system 10 may position and apply a label 208 in a comer on the face 202 of a package 200. As shown in Fig. 2, the package 200 includes differently shaped faces 202, 204, and 206. Placement of the label 208 in the comer of the package 200 may be accomplished regardless of whether the box was placed on the conveyer belt 64 in the position shown in Fig. 4A or positioned as shown in Fig. 4B or otherwise rotated or angled in some other way.

[0076] In some embodiments, the labeling system 10 may be configured to place a first label on one side or location of a package and to place a second label on another side or location of the package. This labeling may be achieved independently from how the package was received through the entry portal 12. For example, as shown in Fig. 5, the labeling system 10 may be configured to place a first label 208 on the face 202 of the package 200 (e.g., in the upper left hand comer of the package 200) and to place a second label 210 on another face 204 of the package 200. In some embodiments, a single robot 20 may be used to apply each of the first label 208 and the second label 210. However, in some embodiments, labeling system 10 may include more than one robot so that, for example, a first robot may apply one of label 208and label 210 and a second robot may apply the other of label 208 and label 210. In some embodiments, labeling system 10 may be configured to detect a seam 216 of the package 200 and to position one or more labels 210 over the seam 216. In some embodiments, labeling system 10 may be configured to apply one or more labels to an open box or package. For example, as show n in Fig. 7, a first label 208 may be applied on a side 205 of the open box 203. The labeling system 10 may further be configured to drop a flyer or pamphlet 207 inside of the open box 203.

[0077] In some embodiments, the labeling system 10 may be configured to select a given label based on a type of package received. For example, labeling system 10 may be configured to scan a package using a 3D scanning system or other detection system 62 such as may be embodied as one or more cameras configured so as to collect image data for the package and identify various characteristics or physical properties of the package (e.g., the package’s size and shape). As further described herein, detection system 62 may generally be used to collect data suitable to map at least the surface of an object and provide data related to the object’s shape. This data may then be used so that labeling robot 20 may position a label at a specified position or best available position for the object. However, in some embodiments, scanning of packages in this manner may also facilitate identification of different types of packages as may be useful, for example, when tw o or more different types of packages may be received on a common packaging or labeling line as may be the case in some multi-package orders. For example, measurement of physical properties of the package may be used to define property values that may be compared to a lookup table of property values such as may relate different property values to a given package type. The labeling system 10 may then select a certain label from one of the label printers 16A, 16B, and 16C as appropriate for the particular type of package identified.

[0078] This protocol or related protocols may in some embodiments be used as an error check procedure useful for minimizing errors when a plurality of different types of packages are meant to be labeled using a single labeling system, for example. For example, other methods for establishing a package type such as reading of a barcode, direct user or customer input of this information, or other techniques known in the art may also be used to determine the identity of a package. Identification of physical properties of packages (e.g., measurement of property values of packages and use of those values for identify ing package type) may be used in combination with those other methods and techniques for package or package type identification as may sometimes be applied in in error check protocols and methodologies.

[0079] In some embodiments, a head unit of a robot may further include a barcodereader. Advantageously, having the barcode reader integrated on the head of a pick and place robot may allow for simultaneous or near simultaneous placement of labels on objects and for use of the barcode reader for label verification. For example, a barcode of a label (see barcode 201, as shown on the label 208 of Fig. 5) may be read as part of consecutive or nearly consecutive operations in a method of applying the label to an object. For example, as a robot head unit 300 (or other head unit described herein) lifts off from the object it may automatically verify the identity of the label before engaging in further activities and while the object remains present within the movement field of the robot. Still, in other embodiments, a barcode may be read while a head unit is positioned for retrieval of a label such as when the label is held on a tray (See Fig. 29. for example). This may, for example, be accomplished without the robot 20 returning to a home position or otherwise engaging another object for labeling. Generally, when a label is applied to an object in this way the placement or application of a label and reading of its barcode may be considered a part of an integrated process in applying the label to the object. In some embodiments, this may be accomplished without having to rescan the object. Consecutive operations of application of a label and reading of a barcode may be accomplished with the object held in place. Alternatively, consecutive operations involving applying a label and reading of the label’s barcode may be accomplished without having to pause movement of objects.

[0080] This approach may. for example, be compared with other approaches including approaches wherein a barcode reader is placed on a separate head of a robotic system or where different barcode readers (e.g., different readers dedicated to reading a barcode placed in a particular position or face of a box) are included in a labeling line to measure barcodes as may be placed in different positions on a package. Particularly, embodiments wherein a barcode reader is integrated into a head unit of a pick and place robot and configured for control as described above may provide significant cost and time savings in labeling systems and methods. This print and read system may be used as an error check methodology so as to help minimize errors in labeling. In some embodiments, any combination of the above methodologies and procedures may be used to reduce or eliminate errors in labeling of packages or other objects.

[0081] In some embodiments, the entry portal 12 may comprise a roller or other style conveyor 34 configured for feeding an object into a labeling area. For example, as shown in Fig. 1 and Fig. 2, the entry portal 12 may comprise both a feed system and an associated opening through which objects may enter the labeling area. In some embodiments, an entry portal 12 may include an entry chute such as may, for example, be formed from one or morepanels generally defining an opening through which objects may be received. Similarly, exit portal 14 may comprise an opening though which labeled objects may exit through.

[0082] Generally, the frame 22 may form the body of robotic labeling system 10 and supports other components of the system 10. The frame 22 or guards attached thereto may also sen e to generally block a user from coming in contact with a moving robotic system or other zone. User accessible areas of the frame may sometimes include a light curtain or other safety enhancing feature.

[0083] As shown in Fig. 1 , the frame 22 may include four vertical support members 38, 46, 48, 58. The support members 38, 46, 48, 58 are connected to the base 60. Base 60 may, for example, be comprised of a front plate 68, a backplate 66 and a plurality of slats 72. Base 60 may, for example, provide a housing at which various system components including computer resources, power resources, or other system components may be disposed. In the illustrated embodiment, the labeling system 10 includes wheels 28 such that the system may be easily moved. Adjustable or dropdown legs 26 may be positioned to secure the labeling system 10 in place once the labeling system 10 is moved to a desired location or the system 10 may be secured in place in some other suitable way.

[0084] As shown in Fig. 1, a support bridge 24 may be connected to the frame 22. The support bridge 24 may be used to position an imaging or shape identification system 62 (also referred to herein as identification system 62) in position for imaging an object 200. In some embodiments, the support bridge 24 may be fixedly secured to the frame. Alternatively, a support for identification system 62 may be coupled to the frame differently or otherwise positioned for use in some other way. For example, components of identification system 62 such as cameras may be adjustably mounted to the frame 22. In some embodiments, components of identification system 62 may also be configured for adjustment. For example, one or more optical elements or other elements of a camera or other imaging device of identification system 62 may be actuated so as to adjust a focal point or working range of a camera, for example.

[0085] As shown in Fig. 2, one or more components of identification system 62 may be secured to the support bridge 24 so as to position the system for scanning objects that pass through the entry portal 12. For example, objects may be scanned or otherwise imaged after they pass through the entry portal 12. More generally, objects may be scanned or otherwise imaged at any suitable position or combination of positions. For example, in some embodiments, objects may be scanned at least once at a position upstream of labeling components 18. However, in some embodiments, imaging or shape identification system 62may comprise a camera or other imaging component built into the robot 20. For example, a camera 62 may be included in a head unit 300 (or other head unit as described herein) of the robot 20 so that operations otherwise performed by identification system 62 may be accomplished an object moves into the range of travel of robot 20.

[0086] In some embodiments, a package 200 may be scanned or otherwise probed by the identification system 62 using a single camera as may be capable of taking a 3-Dimensional image of the package 200. In other embodiments, the package may be scanned using a group of cameras. In some embodiments, two or more cameras may be positioned at different locations within a single labeling station. For example, a first camera may be configured to perform 3D scanning of an object so as to collect data useful for establishing the shape and position of the object. Additional cameras may be used to verify the shape and / or position of the object or to perform other functions. For example, a second or additional camera may sometimes be disposed for imaging at a position after a label has been applied such as may be used to verify various attributes for an applied label, including, for example, any combination of the identity, position, and orientation of the applied label.

[0087] Generally, any suitable system (e.g., a 3D scanning system) may be used for collecting data for an object. For example, in some embodiments, a camera may be equipped with a pulsed light source and detection optics suitable for measuring a time of detection of scattered or reflected light to establish distance to an imaged point on an object. For example, a camera may be a LIDAR (light detection and ranging) camera suitable to perform distance measurements and allowing for object mapping. In some embodiments, a camera or other component as may be part of identification system 62 may comprise a part of the robot 20. For example, image scanning and shape identification functions otherwise executable by identification system 62 may be performed using sensors disposed on a head unit of a robotic labeler. For example, a camera or other component of identification system 62 and robot 20 may be housed as a single component in a labeling head as described herein. In some embodiments, a camera or other component of identification system 62 and robot 20 may be mounted to a common frame or those components may be mounted to different frames. Generally, imaging and shape identification system 62 and the robot 20 may share computing resources.

[0088] In some embodiments, data obtained using detection system 62 may be used to determine the position, size, geometry, and other relevant physical properties of a package. For example, in some embodiments, a 3-D vision system may be configured to identify a box seam as may sometimes be used when it is desirable to label over the seam. In another example, abox shape may be identified as may allow for labeling of non-flat surfaces or other irregularities in a box such as angled edges or faces of a box that may be bowed outwards. In some embodiments, a tented box may be labeled.

[0089] In some embodiments, data may be obtained using identification system 62 (as may be embodied in the form of a camera) and sent to a separate computer resource for analysis. However, in some embodiments, at least some data processing may be performed using computer resources included in the imaging components of identification system 62. Thus, in some embodiments, processing of data may be performed using computer resources of identification system 62, other computing resources, or both. In some embodiments, at least initial processing of image data may be executed before the image data is used for establishing or finally establishing one or more physical characteristics of an object. For example, at least some initial processing of image data may be performed by computing resources of identification system 62. If this initial processing indicates that image data is insufficient either or both of the identification system 62 and conveyer system may be controlled so as to allow for additional image data to be taken. For example, if image data is insufficient to properly define one or more comers or other features of a box (e.g., edge shape or surface shape) because a detected signal to noise is low or if the image data is otherwise compromised, either or both of the identification system 62 and conveyer system may be controlled so as to allow for additional image data to be collected. In some embodiments, additional image data may be collected with or without adjusting one or more characteristics of a camera (e.g.. focus, position, or other characteristic of the camera as may be used to improve image quality) or other component of imaging and shape identification system 62. Generally, identification system 62 may send and receive data when communicating with other system components by any suitable means such as through a wireless connection or a wired connection, for example.

[0090] In some embodiments, any suitable means may be used for moving a package (or other object) between the entry portal 12 and the exit portal 14. For example, in some embodiments, a belt system, rather than exposed rollers, may be used. A belt 64 may, for example, provide for smoother motion of objects moving through the system while also having a higher coefficient of friction than rollers. In some embodiments, belt 64 may comprise a noslip surface such as may be provided by a suitable coating, for example. Generally, a camera or other imaging device may be positioned at a suitable distance from the belt 64 to properly monitor a zone about which an object may pass. While many colors may work for the belt 64, black generally creates a high contrast for most objects expected to go through the system. Of course, a conveyor system may be tailored for the system 10 and for a particular camera (or forparticular objects to be labeled) and protocol for collecting data. In some embodiments, a belt system may move continuously during normal operation. For example, in the absence of certain events (e.g., when a box jams during travel or when moving through the exit portal 14) belt 64 may move continuously. In other embodiments, a belt system may be controlled so as to slow down or stop during certain operations. For example, a belt system may slow' down or stop when an object is being imaged (or if the system detects that the object was not correctly imaged). In some embodiments, a belt system may slow down or stop when a label is being applied to an object.

[0091] As shown in Fig. 1, an object 200 may be moved along the belt 64 so as to engage with labeling components 18 of the system. These components may include, for example, the robot 20, and the plurality of label printers 16 A, 16B, and 16C. In some embodiments, a pad or surface for receiving rejected labels may also be provided. Generally, labeling components 18 of the system may be controlled so as to execute operations related to labeling including, for example, printing of labels, selective retrieval of labels from any combination of available label printers, and application of labels on a given object.

[0092] In some embodiments, labeling components may be controlled using a control system including one or more computing resources, referred to herein as communications and processing system 40. Fig. 8 is a schematic diagram of an embodiment of communications and processing system 40. Generally, communications and processing system 40 may be embodied in one or more computing resources such as may be distributed in different computer systems of robotic labeling system 10. Communication and functionality for the system may, for example, be facilitated through softw are installed on various computer modules or submodules making up the system, through apps onboard the system, or any combinations thereof. For example, in some embodiments, one application or module may run an interface for the robot arm. Another application may, for example, communicate with host systems of a customer such as a commercial shipper, such as FedEx or UPS, for example.

[0093] As shown in Fig. 8, the processing system 40 may include a central integration module 140. Central integration module 140 may be configured for communication with individual modules and sub-module of the system through any suitable means including, through a wired or wireless connection. Central integration module 140 may, for example, sen e to coordinate the different data that may be organized to facilitate printing and other system functionalities. For example, central integration module 140 may receive specification data for label printing from one or more customers as may be routed through the customer communication module 146 and coordinate that information with robotics module 152 and / orprint control module 148 for the printing, retrieval, and placement of labels on packages. The central integration module 140 may also communicate with various displays and user I / O input output devices used for system control and management.

[0094] As shown in Fig. 8, the various modules and sub-modules of the system may include, for example, a robotics sub-module 142 and imaging sub-module 144. Those systems may be closely tied in functionality with tasks sometimes being controlled using a common computer resource such as may comprise robotics control module 152. As shown therein, the robotics control module 152 may coordinate operations executed by the robot 20 and the detection system 62. A customer communications module 146 may receive data from one or more input devices 150. For example, input devices 150 may provide data identifying preferences or requirements for position and / or orientation of applied labels may communicate through customer communications module 146. An input device 150 may, for example, be embodied as a computing device, smartphone, or other communicative device. Printing control module 148 may generally coordinate control of the label printers 16A, 16B, 16C.

[0095] As shown in Fig. 9, an object 200 may be moved along the belt 64 so as to generally engage with labeling components 18 of the system. The robot 20 may. for example, receive a command from processing system 40 indicating that the robot arm 302 should be moved so as to position ahead unit 300 (or other head unit as described herein) for retrieval of a label from the first label printer 16A (or, alternatively, as the case may be, from one of the additional printers 16B, 16C). As shown in Fig. 10. the robot 20 may then position a retrieved label for application on the object 200. In some embodiment, the robot 20 may be a multi-axis pick-and-place robot including one or more of the custom built head units 300, 330, 370, 470. Head units as described herein may sometime be referred to as robotic or robot labeling heads.HEAD UNITS FOR ROBOTIC LABELERS AND LABEL PRINTERS

[0096] Generally, the various head units 300, 330, 370, 470 as described herein may be configured for retrieving labels from one or more label printers, including, for example, any of the three label printers 16A, 16B, 16C as shown in Figs. 1, 2, 9, & 10. Such label printers, may, for example, contain labels with different characteristics including different physical size. An embodiment of a head unit 300 is shown in Figs. 11-20, for example. An embodiment of a label printer 16 is shown in Figs. 21-24. Figures 25-30 show how a robot 20 with a custom head 300 may interact with the label printer 16. For example, in some embodiments, the labelprinter 16 may include a fan 352 configured for pushing a label 313 against a shaped alignment tray 350 (e.g., including a plurality of shaped bars or rails) or other mount. Head unit 300 may include reliefs 320 forming a corresponding shape allowing for shaped tray 350 to seat therein when the head unit 300 engages with the tray 350. As the tray 350 seats within the head unit 300 coordinated application of suction may help to secure a label to a plate 306 (sometimes referred to herein as pick plate 306) of the head unit 300.

[0097] As shown in Figs 11-20, the head unit 300 may include a housing 304 as may be mounted to the robotic arm 302 of robot 20. For example, head unit 300 may be mounted to robotic arm 302 through any suitable coupling or joint as suitable for facilitating operation and movement of the head unit 300. The plate 306 may be coupled to the housing 304 at a bottom side of the head unit 300. As shown in Fig. 12 & Fig. 13, the plate 306 may include a plurality of slots 308 (as may be part of a grill) though which air may pass into the housing 304. A fan 310 (see Fig. 18 & Fig. 20) may be configured to draw air into the housing 304 as may be used to provide suction for holding labels.

[0098] The plate 306 may be mounted so as to enable adjustment of the plate's position within the head unit’s housing 304. For example, the plate 306 may be mounted so as to allow for adjustment between an extended configuration (see Fig. 17 and Fig. 18) and a compressed configuration as shown in Fig. 19 and Fig. 20. For example, as the head unit 300 engages with a package 200, the plate 306 may move between the extended configuration shown in Fig. 17 & Fig. 18 to a compressed configuration as shown in Fig. 19 & Fig. 20. Movement of the plate 306 may generally help the head unit 300 to adapt to variations in surface topography and shape of a package. In some embodiments, adjustment of the plate 306 may be accomplished using any suitable means. For example, electronically controlled actuators may be positioned at the comers of the plate 306. As the head unit 300 approaches the package the surface topography may be measured using suitable sensors. The plate 306 may the be adjusted using actuators so as to account for variations in topography.

[0099] In some embodiments, as shown in Fig. 18 & Fig. 20, for example, the plate 306 may be coupled with the body or housing 304 of the head unit 300 through a plurality of screws 314. Each of the plurality of screws 314 may be biased in a forward or extended position (see the extended configuration shown in Fig. 17 & Fig. 18) using a spring 316. Springs 316 may compress or expand to allow the screws 314 to translate (see the extended configuration shown in Fig. 19 & Fig. 20) in response to a reactive force provided on the head unit as it engages with a package. For example, in some embodiments, four different pairs of screws 314 and springs 316 may be arranged at each of the four comers of the head unit 300. Of particularnote, as best shown in Fig. 20, when the head of a given screw 314 is forced to move away from the spring bias position as may be the case during package engagement, the head 281 of the screw 314 may move into a sized cavity 283. Particularly cavity 283 may be sized or “oversized” versus what would be required to receive the head 281. Accordingly, the screw 314 may rock or move within the cavity 283. As shown in Fig. 20, the overall cavity 279 about which the screw 314 is seated may be shaped to allow such movements. For example, screw may rock or move when positioned as shown in Fig. 20 within shaped cavity 279. Shaped cavity 270 may, for example, generally resemble a conical funnel so that the screw 314 is supported within the cavity 270 and rocks about the funnel constriction region 277 when positioned in a compressed configuration. Thus, with rocking movement or other similar motions supported by each of the screws 314, the head unit 300 may generally move in various ways when adjusting to the surface topography of a given package.[000100] When the head unit 300 disengages from a package, springs 316 may bias the plate away from the housing so that they generally return to their extended positions as shown in Fig. 18. As screw head 281 moves forward it may be guided by conical walls 275 forming the lower portion of cavity 283. That is, springs 316 may bias the screws 314 along a guided path formed by conically shaped walls 275 so that the screws 314 and the plate 306 automatically returns to a normal seated position thereby returning the plate 306 to a reproducible home or level position. In some embodiments, the screw head may be conical and the shaped walls 275 may form a corresponding conical recess. The spring may urge the conical head of the screw to seat in the conical recess, thereby centering the screws in their respective funnels and consistently returning the plate to the same extended position. As further described herein, see Fig. 26 & Fig. 29, in this reproducible position reliefs 320 may be positioned so as to reproducibly engage with corresponding rails or other structure formed in tray 350 of label printer 16.[000101] In some embodiments, a head unit 300 may include multiple spans or regions of suction so that it may better hold labels of different sizes. For example, the head unit 300 may engage with and retrieve labels of a first size from one of the label printers 16A, 16B, 16C. The head unit may also engage with and retrieve labels of a second size (a larger size, for example) from another of the label printers 16A, 16B, 16C. In some embodiments, the head unit may apply suction selectively to different areas or regions of the plate 306. For example, as shown in Fig. 16, head unit 300, may, in some embodiments, comprise each of four different cavities. In some embodiments, suction pressure may be selectively applied to any combination of cavities or regions of a head unit 300. For example, one or more adjustabledampers may be selectively actuated so as to selectively apply suction pressure over different regions of the suction head 300. In some embodiments, the head unit 300 may include dampers 346, 472A, 472B as shown in either of the head unit 330 or the head unit 470, for example. Alternatively, another suitable damper or group of dampers may be used. Accordingly, suction pressure may, for example, be applied to different regions of a suction head as may be appropriate for a label of given size.[000102] Fig. 21 shows a perspective view of an embodiment of a label printer 16. The label printer 16 may, for example, be positioned in any of a first, second, or third position indicated respectively by label printers 16A, 16B, and 16C, in the robotic labeling system 10. As shown therein, the label printer 16 may be held in a cartridge 110. Cartridge 110 may, for example, be supported by the frame 22. For example, as shown in Fig. 1. cartridge 110 is supported between front and back support members 54, 56 of the frame 22. Fig. 31 shows the cartridge 110 with cutaway formed in the cartridge walls. As shown therein, cartridge 110 may, for example, include a rail system 470. Advantageously, mounting the printers 16A, 16B, and 16C in this way may provide stability-, accessibility, and quick change out capability for different printer modules. For example, each of the label printers 16A. 16B. and 16C may be held in a mount, carrier or tray that may7be moved forward and back along the rail system 70 such as may allow for refilling of labels during maintenance operations. A label printer 16A, 16B, 16C may for example slide on the rails (as may be needed during maintenance) yet be locked in place and rigidly secured on the rail assembly during label picking or retrieving operations.[000103] In some embodiments, a carrier or tray 110 may house other dispenser tools or machines other than only label printers. For example, sheets of paper could be dispensed for picking and packing operations. Generally, the label printers 16, 16A, 16B, and 16C (or other label printers described herein) may be configured so as to apply different colors and sizes of labels such as to facilitate multi-package labeling.[000104] In some embodiments, label printers 16A, 16B, and 16C may comprise a storage drum 90 for blank labels 92 and peeled backings and a label guide. The guide may help to position the label in an optimal position for ahead unit 300 to retrieve the label. The label may have its backing peeled from the adhesive as the label exits the printer and goes through the guide. The label may then be left hanging by a slim margin of its edge on the adhesive side contacting a lip or other guiding structure. Generally, a head unit 300 may retrieve a label hanging in this way with high fidelity.[000105] While, generally, a head unit 300 may retrieve labels freely hanging by gravity.disturbance of local air flow or other things may sometimes cause the label to prematurely fall from the guide or buckle or move in an unexpected way. In such situations, the head unit 300 may sometimes not be able to correctly retrieve the label or other errors may occur. In some embodiments, herein, label printers may be configured to address these concerns and other concerns.[000106] For example, Figs. 25-28 show an embodiment of a label printer 16. As shown therein, label printer 16 may include, among other things, as described above, a storage drum 90 for blank labels 92 and a guide 94 for dispensing labels. The label printer 1 may further include a fan 352 and associated duct work 354 as may be used to distribute air flow from the fan 352 upon a tray 350. As a label is dispensed from the label printer 16 air flow from the fan 352 may direct the label against the tray 350. In this position, the label may be held for engagement with head unit 300, for example. Generally, air flow from the fan 352 may be greater than any local disturbances in air flow that might be problematic. Thus, the label may be reliably positioned against the tray 350 and held thereon for retrieval.[000107] An embodiment showing different stages in engagement between a head unit 300 and label printer 16 when retrieving labels is shown in Figs. 25-30. For example, as shown in Fig. 25 and corresponding Fig. 28 (showing different views of a first stage in an embodiment for retrieving labels from a printer), a label 313 may be printed using the label printer 16. For example, a label 313 may be printed and guided through printing guide 94. In this process, the label 313 (see Fig. 32) may. for example, be peeled from a liner 315 and fed forward though printing guide 94. As the label is fed forward through the guide 94 it may be directed by air flow provided by fan 352 so as to seat against the tray 350. Duct work 354 may be configured to help distribute air flow provided from the fan 352 so as to hold the label 313 against the tray 350. For example, air flow may be generally uniform across a bottom surface of the label 313 when holding the label 313 against the tray 350 or some other suitable distribution of air flow may be used to hold a label against the tray 350. In some embodiments, one or more rails of the tray 350 may include a notch 354. A notch 354 may help to limit movement of the label 313 on the tray 350. That is, notch 354 may help to confine movement of the label 313 so that it does not slide off the tray 350. As shown in Fig. 24, the notch 354 is shown towards the bottom of the tray. In some embodiments, a pair of notches 354 may be included on the tray. For example, a first notch 354 may be generally disposed towards the bottom of the tray. A second notch 354 may be disposed towards the top of the tray.[000108] As shown in each of Fig. 26 and Fig. 29, head unit 300 may then engage with the tray 350. In some embodiments, engagement between the head unit 300 and the tray 350may be facilitated using one or more reliefs 320 of the head unit 300 (see Fig. 12 & Fig. 13 showing reliefs 320 formed in the plate 306 on the bottom side of head unit 300) configured to receive the tray. For example, each of the three individual bars or rails of the tray 350 may seat within one of the three reliefs 320. Reliefs 320 may, for example, be embodied as grooves. Of course, some other number of bars or rails or other sty le of reliefs 320 may be used. More generally, tray 350 may be formed in other shapes with the plate 306 of head unit 300 being adjusted accordingly.[000109] As the head unit 300 engages with the tray 350 (as shown in Fig. 27 & Fig. 30) suction may be applied. Accordingly, the label 313 may be held to the plate 306 of the head unit using suction. In some embodiments, suction (or full suction) may only be applied once the head unit 300 becomes engaged with the tray 350. For example, one or more dampers may be actuated so that suction may be applied only after the head unit 300 is engaged with the tray 350. In other embodiments, partial suction or full suction may be applied throughout the process of engagement. In some embodiments, as may be seen in comparison of Fig. 28 and Fig. 29, the head unit 300 may approach the tray for engagement along a path (shown by arrow Ai in Fig. 28). Particularly, the angle of approach between the head unit 300 and the tray 350 may help to ensure that suction applied by the head unit 300 works with air flow provided by the fan 352 to help ensure that the label is not pulled off from the tray 350 prematurely before the label is engaged with the head unit 300.[000110] In some embodiments, reliefs formed in the plate 306 may be characterized by a depth Di. The depth Di may be related to a width Wi ofthe rails of the tray (See Figs. 12 and 24). For example, the depth Di may be greater than the width Wi of the rails so that the rails may fully seat in the reliefs. Accordingly, the plate 306 may generally press up against the label 313 and the label 313 decouple from the tray 350 when the head unit 300 is fully engaged with the tray 350. Accordingly, the head unit 300 may hold the label 313 when moving away from the tray 350, as show n, for example, in each of Fig. 27 & Fig. 30.[000111] Another embodiment of a head unit 330 is shown in Figs. 33-35. Fig. 33 is a side elevational view of the head unit 330. As shown therein, the head unit 330 may generally include a housing 334 and a bottom side plate 336. Fig. 34 is a bottom plan view of the head unit 330. As shown therein, in some embodiments, the head unit 330 may include a barcode reader 332 integrated on the plate 336. In other embodiments, barcode readers 332 may be integrated with other plates (such as the plate 306 of head unit 300, or other plates and head units as described herein) so that a barcode reader 332 may be provided on other head units. Head units including an integrated barcode reader 332 may, for example, enable a head unit toboth place labels on each of a plurality of different locations on a package and check the identity of the label. For example, the application and checking of identity of a label may be executed about simultaneously with the label’s application. This may be contrasted with other systems where different barcode readers would be required to read the barcodes of labels in different positions thereby amounting to a significant cost savings.[000112] As shown in Fig. 34, a plurality of fans 338A. 338B may sometimes be provided on a head unit (the fans 338A. 338B are seen through the slots 340 formed on the plate 336). In the configuration shown in Fig. 34 each of left side 338A and right side fan 338B is shown. Thus, suction may be provided by both fans 338A, 338B. Alternatively, only one of the fans 338A, 338B may be used. In some embodiments, the fans 338A, 338B may be used selectively based, for example, on a type of label intended to be added.[000113] In some embodiments, one or more dampers 346 may be provided. The dampers 346 may, for example, allow for rapid and selective application of suction to different regions of the plate 336. For example, as shown in Fig. 35, a damper 346 may generally block the left side of the plate 336. Accordingly, suction may be selectively applied only to the right side of the plate, for example. In some embodiments, one or more dampers 346 may act to seal a plate 306, 336 or one or more regions of a plate from air flow. Accordingly, internal fans 310, 338A, 338B may generally spin at a higher speed than they otherwise may be able to achieve if working against incoming air, for example. Actuation of the one or more dampers 346 (opening of the dampers) may then be used to apply a strong initial pulse of suction as may be used when initially retrieving labels, for example. For example, in some embodiments, one or more dampers 346 may be actuated once a head unit 300, 330 engages with a tray (see Figs. 26 & Fig. 29) so that an initial strong pulse of suction is used during engagement of a label 313 to the head unit 300. 330. In some embodiments, a damper 346 may move laterally (side to side) or translate towards or away from slots 340 or grill 340 during actuation. In some embodiments, a damper 346 may comprise a solid plate, slotted plate, or other suitable shape as may be used to block air flow. For example, damper 346 may comprise a slotted plate with movement of the damper plate 346 selectively blocking air flow when slots of the damper plate are misaligned with slots of the grill or allowing air flow when slots of the damper plate are aligned with slots of the grill.[000114] Another embodiment of a head unit 470 is shown in Figs. 36-41. The head unit 470 may include a plurality of chambers and include dampers for selective application of suction to different chambers. For example, as shown in Fig. 36 and Fig. 37 a portion of the plate 480 has been removed so as to more clearly see the each of the dampers 472A and 472B.The dampers 472A, 472B may be connected, respectively, to actuators 475A, 475B. Fans 474A, 474B may operate to provide air flow to the respective regions 473A. 473B of the head unit. The actuators 475A, 475B may be used to control the respective dampers 472A and 472B. For example, as shown in Fig. 37, dampers 472A, 472B may be opened so that blades for the respective fans 474A, 447B may be seen in each of Fig. 37 and Fig. 41 (showing an open gate condition). Likewise, actuators 475A, 475B may be used to close the dampers 472A, 472B so that blades for the respective fans 474A. 447B may not be seen (and air flow is blocked) in each of Fig. 36 and Fig. 40(showing a closed gate condition).[000115] Another embodiment of a head unit 330 is shown in Figs. 33-35. As shown in Figs. 33-35, in some embodiments, a sensor head 330 may include one or more sensors. For example, a sensor head 330 (or other sensor head described herein) may include any combination of the sensors 345, 347, 349. Generally, such sensors may be secured separately or as part of a sensor assembly wherein two or more of the various sensors 345, 347, 349 may, for example, be disposed together in a sensor assembly unit. Sensors 347 may, for example, comprise reflectance infrared sensors as may be capable of detecting when light emitted therefrom reflects backwards (as may be the case when a label is disposed on top of the sensor 347). For example, as shown in Fig. 34, a head unit 330 may include redundant sensors to monitor if a label has been picked up properly or at all. Generally, labels may have black areas or other oddities that inhibit the reading from a particular sensor. Accordingly, it may be advantageous to have multiple redundant sensors 347 disposed in the head so that if one sensor 347 among a group of sensors does not read other sensors 347 may appropriately read if a label is coupled to a sensor head 330.[000116] In some embodiments, the sensor heads as described herein may be configured to apply labels to boxes that are not perfectly square and flat (or apply labels to other irregular objects). Accordingly a head unit 300, 330 (or other sensor head as described herein) may be built with some compliance. For example, as described herein, the head unit 300 may include a plate 306 mounted to a housing through a plurality of conical screw s and springs. Relative movements between the different screws may enable the plate 306 to move allowing the plate to comply to the surface of a package. In some embodiments, movements of a plate 306 (or plate 336, for example) may be monitored by at least one sensor 345, 347 at each comer of the plate.[000117] In some embodiments, ahead unit 330 (or other sensor as described herein) may contain one or more sensors 349 that allow the head to determine the size, shape, and location of the target box. In some embodiments, the sensors 349 may be configured differently fromthe sensors 347. For example, sensors 349 may include imaging sensors such as may comprise imaging components otherwise described herein with respect to identification system 62. In some embodiments, sensors 349 may allow the robot 20 to identify when a box 200 is present and properly apply a label 313 without the need for a sensor suite outside the robot 20. For example, the sensors 349 may act in place of (or work together with) imaging components described for image shape and identification system 62. The various sensors 345, 347, 349 may be in addition to a barcode reader 332 in the head. In some embodiments, these measurements made be made on a stationary' box or one in motion through the system. In some embodiments, measurements from one or more of the head sensors 345, 347, 349 may help determine if a label can be put on a box while still in motion or if the box needs to be stationary for the operation. In some embodiments, sensors 349 may be configured to measure the reflectance of a part of a box. Reflectance measurement of sensors 349 may, for example, be used to help identify tape as may for example be provided at a box seam. Systems herein may be used to label over such a seam.[000118] In some embodiments, using the systems and method described herein a system may be configured to determine if an object surface is flat or has some other geometry to it. A sensor head may then be properly positioned with respect to the detected surface and apply the label even through a curved surface or otherwise non-flat geometry'. In some embodiments, the sensors 349 or another suitable sensor (e.g., a pressure sensor) of the suction plate in a head unit may allow the system to compute where pressure has been applied to the label and thus contours can be followed during the label application. Alternately, a camera may monitor if and where the head is and has touched the target surface. In some embodiments, the system may have the robot 20 apply a label that spans around a comer of the box. Additionally, the system can detect if the box is something untypical, such a triangular shape, and have the angle of the head adjust to match the target surface of the box. This ability may generally be irrespective of the shape of the label. Generally, any shape of label that can be processed by the printer can be properly applied to an intended box.[000119] In some embodiments, the scanner in the head may read any communicative symbol. This can include colors, shapes, icons, wording, QR-code, bar code, or any communicative symbol that can be printed on a label. In the ty pical labeling center, warning labels may be applied manually to help ensure all of the required labels intended to be applied are actually applied. Systems herein may generally eliminate the need for this manual process by being able to both apply and verify that all of the required labels are present at the end of the labeling process.[000120] Fig. 42 is a perspective view of yet another embodiment of a head unit 370. As shown therein, the head unit 370 may be coupled to adjustable robot arm 302. The head unit 370 may include a housing 372 or body at which other structures of the head unit 370 may be mounted. Fig. 43 shows another perspective view of the head unit 370. As shown in Fig. 43, a plurality of plunger assemblies 374 may form a bottom surface of the head unit 370. The plunger assemblies 374 are also shown in Figs. 44-46. As shown in Fig. 44, plunger assembly 374 may include a plunger 378 coupled with a spring 376. Each plunger may comprise a cylindrical body having a bore 380 extending along the central axis from one end (see first end 363) to the other (see second end 365). A flange may be formed or attached at one end of the cylindrical body. An annular shoulder 395 may be formed or attached to the cylindrical body between the ends thereof. An annular ring 397 such as foam pad 382 or other pliable component suitable for engagement with a label may be mounted to the flange to form the outer face of the plunger assembly. For example, foam pad 382 may generally engage with the label without inadvertently tearing the label. Other suitable materials or components may also be used, such as rubber or silicone. Air may be pulled so as to create a suitable suction for holding labels.[000121] Each plunger assembly may be translatably (see Fig. 51) disposed in abase plate 379 and a guide plate 381. The base plate has a first side 383 and a second side 385. The base plate and guide plate may be disposed parallel to each other and at a fixed distance apart. The base plate and guide plate may each have a plurality of corresponding openings or apertures 377 through which a plunger may travel. A plunger may be disposed in corresponding holes of a base plate and a guide plate and translate therein. The spring and annular shoulder of the plunger may be disposed between the base plate and the guide plate. The annular shoulder of the plunger may be urged against the base plate by the spring, thereby maximally extending the plunger beyond the base plate. Pressure on the flange of the plunger may cause the plunger to translate through the corresponding openings in the base plate and guide plate, thereby causing the annular shoulder to move toward the guide plate and compressing the spring. Releasing pressure on at the flange end of the plunger will allow the spring to return the plunger to a fully extended position.[000122] The base plate may form one side of a housing. The housing may enclose the guide plate. A fan may be disposed on the housing so as to draw air into the housing enclosure through the plunger assemblies. The housing may be divided into sections, with each section having a fan and separate set of plunger assemblies. The section fans may be selectively operated to regulate airflow through different sets of plunger assemblies.[000123] Thus, for example, a head unit 300, 330, 370 may be provided with one or more plates 306, 336 or with a plurality of plunger assemblies. Generally, by including additional plates 306, 336 on a head unit 300, 330 the ability7of the head unit 300, 330 to conform to different or irregular surfaces may improve. Generally, the head unit 370 may be used for labeling any object including those with a generally flat surface or one with an irregular surface topology. For example, as shown in Fig. 47 and Fig. 48 a head unit 370 may be particularly configured for positioning labels 313 on different shapes 384, 386 or on other shapes, for example. In some embodiments, one or more pressure sensors 321 may be included in ahead unit. For example, as shown in Fig. 45 a pressure sensor 321 may be integrated within a plunger assembly 374. In another example pressure sensors 321 may be include among a screw' 314 and spring 316 assembly as shown in Fig. 24, for example. Accordingly, for example, a pressure or force of engagement between a package 200 and a head unit may be measured.METHODS FOR APPLYING LABELS TO OBJECTS[000124] In some embodiments, the systems as described herein, or other suitable systems may be used in related methods for applying labels to an object or for operating a robotic labeler. For example, an embodiment of a method 400 for applying labels to an object is show n in Fig. 49. As shown therein, at step 402, the identity of a package or box to be labeled may be determined. Identification of a package or box may, for example, be used to associate the package or box with an order for a shipment or delivery so that information including, for example, a shipping address and other information may be correlated with the package or box. Additional information about the order may also be received. For example, specification data regarding a preferred or required position and / or orientation for applying a label to the box may also be received. Specification data may, for example, be provided for an individual package or for a package type of which the package is a member. In either case, the specification data may be associated with a given package. In some embodiments, the identity of a package may be determined using any suitable method. For example, in some embodiments, the identity of a package or box may be input into the system (e.g., input by a system user) or the identity of a package or box may be determined by scanning a barcode on the package or box such as may associate the package or box with a given order. In some embodiments, the identity of a package or box may be determined by scanning the package or box using a separate imaging system. For example, scanning of a package or box may be used to determine property7valueof the package or box and then using the determined properties values for identifying a particular package or type of package.[000125] In some embodiments, the identity of a package may be determined using one or more identification strategies, as may, for example, be used in an error check protocol for package identification. For example, in some embodiments, the package or box may be scanned using a sensor suite included on a robotic head unit of a robotic labeler. For example, as the package or box comes into the range of the robot 20, the package or box may be scanned using sensors equipped on the sensor head 330 (or another head unit as described herein). Sensors may be used to collect data used to determine values for physical properties of the package or box which may then be compared with expected properties so as to identify the pack or box to be labeled. Identification of the package in those way may, for example, work individually or in combination with user input and / or scanning of a barcode to identify a package.[000126] As further shown at step 402, other information including, for example, specification or preference data for the position and / or orientation for applying a label to the package or box may also be received. In some embodiments, at least some of this information may, for example, be input from a customer intending to receive the package or box or shipping entity. In this context, the customer may, for example, be an end user, or a retail provider, such as Walmart, for example. A shipping entity may, for example, be a delivery company, such as FedEx or UPS. In some embodiments, receiving information about a package (e.g., specification data for the package) may include providing an application on an input device (such as may be owned and operated by a customer or representative of a shipping company) so as to allow a customer to directly interact with a control system for labeling system. For example, an input device 150 may provide specification data to a control system as may, for example, be routed through customer communications module 146 to robotics control module 152.[000127] As shown at step 404, the box or package may be scanned so as to identify7at least some surface features of the box or package. For example, as shown in Fig. 6. a box or package 200 may be scanned so as to identify the coordinates (xi, yi, zi) for the comer of the box. A position or orientation for applying a label 208 to the box may then be determined. For example, specifications may identify that the comer 214 of the label should be positioned at coordinates (x2, y2, Z2) such as may, for example, position the label a specified distance from the upper left comer 212 of the box. Scanning of the box or package may be executed using a head unit of a robot as described herein and including sensors for scanning the box or package.For example, as the package or box comes into the range of the robot 20, the package or box may be scanned using sensors equipped on the sensor head 330 (or another head unit as described herein).[000128] At step 406, an appropriate label may be retrieved. For example, an appropriate label may be retrieved from one of various label printers (see label printers 16A, 16B, 16C) from an assembly of printers. Each of the label printers may be provided for retrieval using a single robot. For example, as shown in Fig. 1 and Fig. 2, each of the three different label printers 1 A, 16B, 16C may be positioned (e.g., secured to an overhead from) so that they may be accessed using a single robot 20. At step 408, the label may be applied to the package. In some embodiments, the method 400 may be applied to a box that is meant to receive more than one label. For example, a first label may be received from a first label printer among a group of available printers and a second label may be received from a second label printer among the group of available printers. Advantageously, the method 400 may be applied using a single robot or single labeling station.[000129] In some embodiments, one or more additional steps may be executed in the method 400. For example, in some embodiments, a robot may include a robot labeling head including an integrated barcode reader (see Fig. 35, for example). In some embodiments, a label may be applied and a barcode reader may scan the label for the presence of a barcode as part of an integrated process in applying the label to the object[000130] In some embodiments, data used in the step 402 may be delivered via a computing device, smartphone, or other communicative device to the communication and processing system 40. Alternatively, the information may be directly supplied to the communication and processing system 40. For example, this data transfer may be communicated by wired or wireless modes of communication and, in some embodiments, both options may be provided. Alternately, this information may be supplied by removable data media such as, by way of nonlimiting example, SD cards, floppy disk, zip drive, or any combination thereof.[000131] In some embodiments, processing system 40 will receive information from which it may identify the label to be applied, and the location or surface on which the label is to be applied to the package. Generally, this information may be received as a package enters the labeling area or in some examples prior to such entry. The communication and processing system 40 may then control the robot arm to pick and apply a label. An individual label may, for example, be a shipping label, warning label, or any other package label. In some embodiments, the system may apply one or more of these labels to the target package in anycombination, such as per specifications of a customer, for example. In this context, the customer, which may be, for example, the package owner or a shipping entity.[000132] In some embodiments, data regarding a preference or requirement for applying a label may be delivered via a computing device, smartphone, or other communicative device to the communication and processing system 40. Alternatively, the information may be directly supplied to the communication and processing system 40. For example, this data transfer may be communicated by wired or wireless modes of communication and, in some embodiments, both options may be provided. Alternately, this information may be supplied by removable data media such as, by way of nonlimiting example, SD cards, floppy disk, zip drive, or any combination thereof.[000133] In some embodiments, the system may also be connected to a user's data network to receive necessary data as to the labeling requirements for an operation. This connection and any other may, for example, be hardwired, cellular, Wi-Fi, use other remote communications modality, or any combination thereof. The system may also be in communication with the manufacturing entity or other support facility for maintenance and other support operations.[000134] Notably, with such connections, the requirement for a person to oversee operations may generally be reduced to minimal or may be nonexistent. For example, in some embodiments, a system may clear errors without intervention by a live operator. Such errors can include a stuck box, bad label, mismatched label, change in operation parameters, low label quantity, or other errors.[000135] One class of error may occur, for example, when the data on the target package does not match the expected package information. Such errors may be resolved by segregating the non-compliant box and having it removed from the line. A backup in the flow of boxes may also be accommodated by the system with the system pausing until it senses proper flow has been reestablished.[000136] In some embodiments, a system may take a label deemed unfit for application to the box and then stick the rejected label on a pad for later disposal. The system may alert operational personnel to an issue through network alerts, beeps, or even voice signals indicating the nature of the error. In one example, these alerts may be sent even if the system cleared the error automatically, such as based on user desired settings. For example, after clearing an error, the system may reinitiate operations without human intervention in the case of most errors.[000137] Communication and functionality’ for the system may, for example, be facilitated through software the operations facility installs on their computers, through appsonboard the system, or any combinations thereof. For example, in some embodiments, an application may run an interface for the robot arm. Another application may, for example, communicate with a commercial shipper, such as FedEx or UPS. In another example, another app may communicate with a host system.[000138] In some embodiments, when there is no customer preferred positioning of the label (see step 404), the system may determine a suitable application point for the label based on the scanned data and information concerning the size and shape of the label to be attached. For example, in some embodiments, a suitable application point may be a point on the box that is generally easiest to find or that is most likely to provide good adherence. For example, as shown in Figs. 3-6, a box or package 200 may include faces or sides of different sizes or shapes. In some cases, one or more of the faces or sides 202, 204. 206 may be found to include a non- critical defect such as a bowed or warped surface. In some embodiments, systems and methods herein may be configured to apply a label to any face or side 202, 204, 206 that is most pristine and for which the best adherence of a label may generally be achieved.[000139] In some embodiments, the method 400 may be paired with a method 420. Alternatively, the method 420 may be executed as a standalone method performed by systems as described herein or the method 420 may be performed using some other suitable system. The method 420 is shown in Fig. 50. As shown therein, the method 420 may include picking and placing a label on an object. Such operations may, for example, include executing steps as described above. For example, as shown at step 422. a label my be selected for application to an object. Together with selecting a label other preference data (e.g., preferred location and / or orientation) of the label may also be determined. As shown at step 424, one or more steps may be executed to verify that the correct label has been applied.[000140] In some embodiments, the application arm may be a multi-jointed robotic arm with a head that picks the label from the guide of the appropriate printer and transfers the label to the target location on the package. Generally, the multi-joint configuration of the arm 302 allows the arm to apply a label to any side of the package that is not in contact with the conveyor belt. Furthermore, this configuration may also allow the arm to adjust to and apply a label on a surface that is not perpendicular or parallel to the conveyor. If a label is rejected after being printed, the arm may then dispose of the rejected label by placing said label on a rejection pad adjacent to the arm’s base 301 (See Figs. 9 and 10) for later disposal.[000141] In some embodiments, more than one robot 20 or robot arm 302 may be used. For example, two or more robots 20 or robot arms 302 may allow a system to accomplish various operations as described herein simultaneously. Generally, a number of robot 20 orrobot arms 302 may be limited by available space and cost considerations. Additional printers or other dispensers may also be added for additional arms. Generally, a number of printers per arm may be limited by the arm's reach. In some embodiments, a robot 20 or robot arm 302 may be positioned on a moveable base. For example, a base 301 may be mounted to a rail and controlled using one or more actuators (e.g., electronically or hydraulically actuated cylinders). Accordingly, a single robot 20 may, for example, be moved as appropriate to interact with a number of different printers.[000142] Although the foregoing specific details describe certain embodiments of this invention, persons of ordinary skill in the art will recognize that various changes may be made in the details of this invention without departing from the spirit and scope of the invention as defined in the appended claims and other claims that may be drawn to this invention and considering the doctrine of equivalents. Among other things, any feature described for one embodiment may be used in any other embodiment, and any feature described herein may be used independently or in combination with other features. Also, unless the context indicates otherwise, it should be understood that when a component is described herein as being mounted or connected to another component, such mounting or connection may be direct with no intermediate components or indirect with one or more intermediate components. Therefore, it should be understood that this invention is not to be limited to the specific details shown and described herein.

Claims

CLAIMSWhat is claimed is:

1. A robot labeling head comprising: a housing configured for mounting to a multi-axis robotic arm; a pick plate coupled to the housing so as to form a first side thereof, the pick plate comprising: one or mor reliefs configured for receiving one or more rails of a tray of a label printer, the tray being configured for holding a label dispensed from the label printer; the pick plate forming a plurality of apertures through which air may pass into the housing, the pick plate coupled to the housing so as to permit movement of the pick plate with respect to the housing when the pick plate is pressed against an object; and a fan mounted to the housing and disposed so as to draw air into the housing through the plurality of apertures.

2. The robot labeling head of claim 1, each of the one or more reliefs comprising a width greater than a corresponding width for said one or more rails, the tray being fully seated within the reliefs when the robot labeling head is engaged with said tray.

3. The robot labeling head of claim 1 , the pick plate being coupled to the housing using a plurality of screw s and springs, the springs being configured to bias the screw s so as to hold the pick plate in an extended position.

4. The robot labeling head of claim 1, the pick plate being coupled to the housing using a plurality of screw's and springs, the springs being configured to bias the screw s so as to hold the pick plate in an extended position, said one or more reliefs being positioned for receiving the one or more rails of said tray when the pick plate is positioned in said extended position and the robot labeling head engages with said tray.

5. The robot labeling head of claim 1 the pick plate being coupled to the housing using a plurality' of screw s and springs, the springs being configured to bias the screw's so as to hold the pick plate in an extended position and to allow the pick plate to adopt a compressed configuration when engaging with said object.

6. The robot labeling head of claim 5 wherein the plurality of screws comprises a group of four screw s positioned at respective comers of the pick plate.

7. The robot labeling head of claim 5 wherein each of the plurality of screws is configured to recede into a cavity when the pick plate is forced into a compressed configuration.

8. The robot labeling head of claim 7 wherein said cavity is sized so as to allow a head for a first screw among the plurality of screws to tilt when the first screw is receded into the cavity.

9. The robot labeling head of claim 8 wherein said cavity is shaped to guide the first screw forward when the pick plate transitions from the compressed configuration to an extended configuration, the cavity' shaped to limit movement of the first screw so that it supports the pick plate in a position that aligns the one or more reliefs for receiving the one or more rails of the tray.

10. A robot labeling head comprising: a housing configured for mounting to a multi-axis robotic arm; a pick plate coupled to the housing so as to form a first side thereof, the pick plate comprising: one or mor reliefs configured for receiving one or more rails of a tray for a label printer, the tray being configured for holding a label dispensed from the label printer; the pick plate forming a plurality of apertures through which air may pass into the housing, the pick plate coupled so as to permit movement of the pick plate with respect to the housing when the pick plate is pressed against an object; a fan enclosed by the housing and disposed so as to draw air into the housing through the plurality of apertures; and a damper movably coupled to the first side, the damper being adjustable between a closed position in which the damper substantially prevents air from being draw n into the housing through the plurality of apertures and an open position in which air flow may flow through the plurality of apertures.

11. A robot labeling head comprising: a housing configured for mounting to a multi-axis robotic arm; a pick plate coupled to the housing so as to form a first side thereof, the pick plate comprising: one or mor reliefs configured for receiving one or more rails of a tray for a label printer, the tray being configured for holding a label dispensedfrom the label printer; the pick plate forming one or more groups of apertures through which air may pass into the housing, the pick plate coupled so as to permit movement of the pick plate with respect to the housing when the pick plate is pressed against an object; a first fan enclosed by the housing and disposed so as to draw air into the housing through at least one of the one or more groups of apertures; and a first damper translatably coupled to the first side, the damper being adjustable between a closed position in which the damper substantially prevents air from being drawn into the housing through at least one group of the one or more group of apertures.

12. A robot labeling head comprising: a housing configured for mounting to a multi-axis robotic arm; and a pick plate coupled to the housing so as to form a side thereof, the pick plate being configured for applying a label to an object, the pick plate including a barcode reader.

13. The robot labeling head of claim 12, the robot labeling head being configured for control so as to apply the label to said object and to read a barcode included on the label as an integrated process in applying the label to the object.

14. The robot labeling head of claim 13, the robot labeling head being configured for control so as to read the barcode before applying the label to said object.

15. The robot labeling head of claim 12 wherein the robot labeling head is configured for applying said label before the robot returns to a home position or engages with another object.

16. A robot labeling head comprising: a housing configured for mounting to a multi-axis robotic arm; a pick plate coupled to the housing so as to form a side thereof, the pick plate forming a plurality of apertures through which air may pass into the housing, the pick plate coupled so as to permit movement of the pick plate with respect to the housing when the pick plate is pressed against an object; and a fan enclosed by the housing and disposed so as to draw air into the housing through said plurality of apertures; the pick plate further including a barcode reader, the robot labeling head being configured for control so as to apply a label to said object and to read abarcode included on the label as an integrated process in applying the label to the object.

17. The robot labeling head of claim 16 wherein the robot labeling head is configured for applying said label and then reading the barcode without having to rescan said object..

18. The robot labeling head of claim 16 wherein the robot labeling head is configured for applying said label and then reading the barcode without stopping the object.

19. The robot labeling head of claim 16 wherein the robot labeling head is configured for applying said label and then reading the barcode before the object is moved past a region of travel allowed for said multi-axis robotic arm.

20. The robot labeling head of claim 16 wherein the robot labeling head is configured for applying said label before the robot returns to a home position or engages with another object.

21. A robot labeling head comprising: a housing configured for mounting to a multi-axis robotic arm; a pick plate coupled to the housing so as to form a side thereof, the pick plate forming a plurality of apertures through which air may pass into the housing, the pick plate coupled so as to permit movement of the pick plate with respect to the housing when the pick plate is pressed against an object; a fan enclosed by the housing and disposed so as to draw air into the housing through said plurality of apertures; and a sensor system configured for scanning said object and for collecting data used for positioning said label on the object.

22. The robot labeling head of claim 21 wherein said sensor system comprises a LIDAR sensor system.

23. The robot labeling head of claim 21 further comprising a barcode reader.

24. The robot labeling head of claim 21 further including at least one pressure or force sensor configured for establishing a force or pressure with which the pick plate engages with said object.

25. A robot labeling head comprising: a pick plate having a first side and an opposing second side, the first side forming one or more reliefs configured for receiving one or more rails of a tray of a label printer; the pick plate further forming a plurality of apertures through which air may pass; anda fan disposed at the second side so as to draw air through the plurality of apertures.

26. A robot labeling head comprising: a base plate having a plurality of first apertures, the base plate having a first side and an opposing second side; a guide plate disposed a fixed distance from the base plate and substantially parallel to the base plate, the guide plate having a plurality of second apertures corresponding to the plurality of second apertures; a plurality' of plunger assemblies, each plunger assembly comprising: a cylindrical plunger forming a bore through which air may pass, the plunger having a first end and a second end, the first end having a flange, the plunger having an annular shoulder formed between the first end and the second end; a spring slidably disposed on the plunger between the shoulder and the second end of the plunger; and a pliable annular ring affixed to the flange; and each plunger assembly being translatably disposed in one of the plurality of first apertures and in a corresponding one of the plurality of second apertures such that the plunger is captured by the guide plate at the plunger second end and captured by the base plate between the annular shoulder and the flange, the spring being contained between the guide plate and the annular shoulder so as to translatably bias the annular shoulder toward the first side of the plunger base plate, the flange being disposed on the second side of the plunger base plate.

27. The robot labeling head of claim 26, further compnsing a fan disposed so as to draw air through the plunger assembly bores from the first end to the second end.

28. The robot labeling head of claim 26, further comprising a pressure sensor disposed on a plunger assembly.

29. The robot labeling head of claim 26. further comprising: a housing forming an enclosure, the base plate forming one side thereof and the guide plate being enclosed by the housing; and a fan disposed on the housing so as to draw air through the plunger assemblies.

30. A robot labeling station comprising: a robot including a multi-axis robotic arm;a robot labeling head comprising: a housing configured for mounting to said multi-axis robotic arm; a pick plate coupled to the housing so as to form a first side thereof the pick plate comprising: one or mor reliefs configured for receiving a tray of a label printer, the tray being configured for holding a label dispensed from the label printer; the pick plate forming a plurality of apertures through which air may pass into the housing, the pick plate coupled to the housing so as to permit movement of the pick plate with respect to the housing when the pick plate is pressed against an object; and a fan mounted to the housing and disposed so as to draw air into the housing through the plurality of apertures; and said label printer.

31. The robot labeling station of claim 30, the label printer further comprising a fan configured for directing air flow over the tray so as to direct said label against the tray.

32. The robot labeling station of claim 30, the tray including one or more rails, at least one of the one or more rails forming a stop configured to help prevent the label from falling off of the tray.

33. The robot labeling station of claim 32 wherein the stop comprises a notch.

34. The robot labeling station of claim 30 wherein the tray including one or more rails, at least one of the one or more rails including a pair of notches configured to help prevent the label from falling off of the tray.

35. The robot labeling station of claim 30 wherein said label printer is part of a group of label printers disposed within a working range of the robot.

36. The robot labeling station of claim 35 further comprising a control system, the control system being configured for instructing the robot to retrieve a label from any of a plurality of label printers among said group of label printers.

37. A method of applying labels to a package using a robot including a head unit for applying labels and including a barcode reader, the method comprising: identifying a package needing a label as part of a shipment or delivery; receiving information associate with the package, said information including specification data including at least one of a position and an orientation at which the label should be applied;scanning the package so as to identify at least one surface feature of the package; retrieving the label from a first label printer available to the robot from a plurality of available printers disposed in a working range of the robot; and applying the label to the package in an integrated process wherein the label is both applied to the package according to the specification data and a barcode reader positioned on a head unit is used to scan the label for a barcode of the label.

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