Case sealer

Abstract

Various embodiments of the present disclosure provide a case sealer including a frame, a top-head-assembly support, a top-head assembly configured to support a tape cartridge that is configured to support a tape roll, an actuator support, and a first actuator supported by the actuator support. The top-head assembly is connected to the top-head-assembly support and vertically movable with the top-head-assembly support relative to the frame. The first actuator is operably connected to the top-head-assembly support and the top-head assembly and configured to vertically move the top-head-assembly support and the top-head-assembly relative to the frame and the actuator support between a lower position and an upper position.

Description

CASE SEALERPriority

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 603,320, filed November 28, 2023, the entire contents of which is incorporated herein by reference.Field

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

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

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

[0005] To seal a case using an automatic random case sealer, an actuator moves the top head to the height of the case before the case reaches the top head, such as based on feedback from an upstream sensor configured to sense the height of the case. The actuator maintains the top head at that height as a conveyor moves the case beneath the top head and the drive belts move the case past the tape cartridges, which apply tape to the case.

[0006] One issue with certain random case sealers is that the masts are sized and positioned such that it can be difficult for an operator to remove the tape cartridges to repair them or replace the tape roll. More time spent removing and replacing the tape cartridges means more downtime, which is detrimental. Another issue with certain random case sealers is that the motor in the top-head assembly that drives the upper drive belts is heavy. The heavier the tophead assembly, the more energy required to raise it, lower it, and counterbalance it to avoid crushing the case. The more energy the case sealer uses, the more it costs to operate.Summary

[0007] Various embodiments of the present disclosure provide a case sealer including a frame, a top-head-assembly support, a top-head assembly configured to support a tape cartridge that is configured to support a tape roll, an actuator support, and a first actuator supported by the actuator support. The top-head assembly is connected to the top-head-assembly support and vertically movable with the top-head-assembly support relative to the frame. The first actuator is operably connected to the top-head-assembly support and configured to vertically move the top-head-assembly support and the top-head-assembly relative to the frame and the actuator support between a lower position and an upper position.Brief Description of the Figures

[0008] Figures 1A and IB are front elevational views of one example embodiment of a case sealer of the present disclosure with the top-head assembly in an upper position and a lower position, respectively.

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

[0010] Figure 3 is a perspective view of the case sealer of Figures 1A and IB with certain components removed for clarity.

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

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

[0013] Figures 6A-6I are side views of the case sealer of Figures 1A and IB sealing a case.Detailed Description

[0014] While the systems, devices, and methods described herein may be embodied in various forms, the drawings show and the specification describes certain exemplary and nonlimiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connection of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as coupled, mounted, connected, etc., are not intended to be limited to direct mounting methods, but should be interpreted broadly to include indirect and operably coupled, mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

[0015] Figures 1 A-5H show one example embodiment of a case sealer 10 of the present disclosure and components thereof. While the case sealer 10 is a semi-automatic random case sealer in this example embodiment, it may be an automatic random case sealer or any other suitable type of case sealer in other embodiments. The case sealer 10 includes a base assembly 100, a mast 190, an actuator support 200, a top-head-assembly support 300, a top-head assembly 400, a top-head-actuating assembly 500, an upper-drive-actuating assembly 600, a lower tape cartridge 1000a configured to support a replaceable lower tape roll, and an upper tape cartridge 1000b configured to support a replaceable upper tape roll. As shown in Figure 2, the case sealer 10 includes multiple actuating assemblies and actuators operably connected to and configured to control movement of certain components of the case sealer 10; multiple sensors S1-S5; and control circuitry and systems for controlling the actuating assemblies and the actuators (and other mechanical, pneumatic, electro-mechanical, and / or electrical components of the case sealer 10) responsive to signals received from the sensors S.

[0016] The case sealer 10 also includes a controller 90 communicatively connected to the sensors S to send and receive signals to and from the sensors S. The controller 90 is operably connected to the actuating assemblies and the actuators to control the actuating assemblies and the actuators. The controller 90 may be any suitable type of controller (such as a programmable logic controller) that includes any suitable processing device(s) (such as a microprocessor, a microcontroller-based platform, an integrated circuit, or an applicationspecific integrated circuit) and any suitable memory device(s) (such as random access memory, read-only memory, or flash memory). The memory device(s) stores instructions executable by the processing device(s) to control operation of the case sealer 10.

[0017] The base assembly 100 is configured to align cases in preparation for sealing and to — along with the top-head assembly 400 — move the cases through the case sealer 10 in a direction of travel D. The base assembly 100 supports the lower tape cartridge 1000a, the mast 190, and the actuator support 300. The base assembly 100 includes a base-assembly frame 111, an infeed table 112, an outfeed table 113, a side-rail assembly, and a lower drive assembly. The base assembly 100 defines an infeed end IN of the case sealer 10 at which an operator or an automated system feeds incoming cases into the case sealer 10 via the infeed table 112 and an outfeed end OUT of the case sealer 10 at which the case sealer 10 ejects cases onto the outfeed table 113.

[0018] The base-assembly frame I l l is configured to support various components of the case sealer 10 and is formed from any suitable combination of solid and / or tubular members, plates, and / or other suitable components fastened together. The infeed table 112 is mounted to the base-assembly frame 111 adjacent the infeed end IN of the case sealer 10. The infeed table 112 includes multiple rollers on which the operator can place a case and then use to convey the case toward the top-head assembly 400. The infeed table 112 includes an infeed-table sensor SI (Figure 2), which may be any suitable sensor (such as a photoelectric sensor) configured to detect the presence of a case on the infeed table 112 and, more particularly, the presence of a case at a particular location on the infeed table 112 that corresponds to the location of the infeedtable sensor SI. In other embodiments, another component of the case sealer 10 includes the infeed-table sensor SI. The infeed-table sensor SI is communicatively connected to the controller 90 to send signals to the controller 90 responsive to detecting a case (a case-detected signal) and, afterwards, no longer detecting the case (a case-undetected signal), as described below. The outfeed table 113 is mounted to the base-assembly frame 111 adjacent the outfeed end OUT of the case sealer 10. The outfeed table 113 includes a planar surface onto which the case is ejected after moving past the tape cartridges, though it may include multiple rollers in other embodiments.

[0019] The side-rail assembly is supported by the base-assembly frame 111 adjacent the infeed table 112 and includes first and second side rails 114a and 114b and a side-rail actuator 117. The side rails 114a and 114b extend parallel to the direction D and are movable laterally inward relative to the direction D to laterally center the case on the infeed table 112. The side-rail actuator 117 is operably connected to the first and second side rails 114a and 114b (either directly or via suitable linkages) to move the side rails between: (1) a rest configuration (Figure 3) in which the side rails are positioned at or near the lateral extents of the infeed table 112 to enable an operator to position a case between the side rails on the infeed table 112; and (2) a centering configuration (not shown) in which the side rails — after being moved toward one another — contact the case and center the case on the infeed table 112. The controller 90 is operably connected to the side-rail actuator 117 to control the side-rail actuator 117 to move the side rails 114a and 114b between the rest and centering configurations. The side-rail actuator 117 may be any suitable type of actuator, such as a motor or a pneumatic cylinder fed with pressurized gas and controlled by one or more valves.

[0020] The lower drive assembly is supported by the base-assembly frame 11 1 and (along with an upper drive assembly 420, described below) configured to move cases in the direction D. The lower drive assembly includes first and second lower drive elements 150a and 150b (though it may include only one drive element or more than two drive elements in other embodiments) and a lower-drive-assembly actuator 118 operably connected to the first and second lower drive elements 150a and 150b and configured to drive the first and second lower drive elements to (along with the upper drive assembly 420) move cases through the case sealer 10. In this example embodiment, the lower-drive-assembly actuator 118 includes a motor that is operably connected to the first and second lower drive elements 150a and 150b — which include endless belts in this example embodiment — via one or more other components, such as sprockets, gearing, screws, tensioning elements, and / or a chain. The lower-drive-assembly actuator may include any other suitable actuator in other embodiments. The first and second lower drive elements and may include any other suitable component or components, such as rollers, in other embodiments. The controller 90 is operably connected to the lower-driveassembly actuator 118 to control operation of the lower-drive-assembly actuator 118.

[0021] The lower drive assembly supports a case-entry sensor S3 downstream of the infeed table 112, downstream of the leading-surface sensor S2 (described below), and beneath the top-head assembly 400 so the case-entry sensor S3 can detect when a case enters the area below the top-head assembly 400. As used herein, “downstream” means in the direction D, and “upstream” means the direction opposite the direction D. The case-entry sensor S3 includes a proximity sensor (or any other suitable sensor, such as a mechanical sensor) configured to detect the presence of a case. In other embodiments, the case-entry sensor S3 is supported by the mast 190 or the top-head assembly 400. The case-entry sensor S3 is communicatively connected to the controller 90 to send signals to the controller 90 responsive to detecting the case (a case-detected signal) and no longer detecting the case (a case-undetected signal).

[0022] The base-assembly frame 111 supports a case-exit sensor S5 that includes a proximity sensor (or any other suitable sensor) configured to detect the presence of a case. Here, although not shown, the case-exit sensor S5 is positioned near the outfeed table 113 (downstream of the case-entry and arm-retraction sensors S3 and S4 described below) so the case-exit sensor S5 can detect when a case exits from beneath the top-head assembly 400. The case-exit sensor S5 is communicatively connected to the controller 90 to send signals to the controller 90responsive to detecting the case (a case-detected signal) and no longer detecting the case (a case- undetected signal). In other embodiments, the case-exit sensor S5 is part of the top-head assembly 400.

[0023] The mast 190, which is best shown in Figure 3, is configured to support the actuator support 200. The mast 190 extends vertically from the base-assembly frame 111 and is attached to the base-assembly frame 111 in any suitable manner. Other embodiments of the case sealer do not include a mast that supports the actuator support.

[0024] The actuator support 200 supports the respective actuators of the top-head- actuating assembly 500 and the upper-drive-actuating assembly 600 and helps guide the vertical movement of the top-head-assembly support 300 and the top-head assembly 400. The actuator support 200 includes a first leg 210, a second leg 220, a connector 230, a first guide 240a, and a second guide 240b. The first and second legs 210 and 220 are vertically oriented, spaced-apart in the direction D, and connected to the base-assembly frame 111 at their bottom ends in any suitable manner, such as via fasteners. The connector 230 is fixedly connected to the top ends of the first and second legs 210 and 220 and oriented transversely to the first and first and second legs 210 and 220. The first and second legs 210 and 220 and the connector 230 form a rigid framework atop the base-assembly frame 111. The first and second legs 210 and 220 and the connector 230 are tubular members in this example embodiment, though they may be any other suitable components in other embodiments. The first and second guides 240a and 240b are connected to the connector 230 between the first and second legs 210 and 220 and are spaced- apart from one another. The first and second guides 240a and 240b are configured to receive certain components of the top-head-assembly support 300 — as described below — to help guide the vertical movement of the top-head-assembly support 300. In this example embodiment, the first and second guides 240a and 240b are vertically oriented linear bearings, though they may be any other suitable components in other embodiments. While the actuator support includes two legs and one connector in this example embodiment, it may include any other suitable quantity of legs and connectors in other embodiments.

[0025] The top-head-assembly support 300 supports and is movable with the tophead assembly 400 in the vertical direction. The top-head-assembly support 300 includes a first leg 310, a second leg 320, and a connector 330. The first and second legs 310 and 320 are vertically oriented, spaced-apart in the direction D, and connected to the top-head assembly 400at their bottom ends in any suitable manner, such as via fasteners. The connector 330 is fixedly connected to the top ends of the first and second legs 310 and 320 and oriented transversely to the first and first and second legs 310 and 320. The first leg 310 extends through the first guide 240a of the actuator support 200, and the second leg 320 extends through the second guide 240b of the actuator support 200. This enables the top-head-assembly support 300 — and the top-head assembly 400 connected to it — to move vertically relative to the actuator support 200. The first and second legs 310 and 320 and the connector 330 form a rigid framework. The first and second legs 310 and 320 and the connector 330 are tubular members in this example embodiment, though they may be any other suitable components in other embodiments.

[0026] The top-head assembly 400 is vertically movable relative to the base assembly 100 to adjust to cases of different heights and is configured to move the cases through the case sealer 10, engage the top surfaces of the cases while doing so, and support the upper tape cartridge 1000b. The top-head assembly 400 includes a top-head-assembly frame 410, an upper drive assembly 420, a leading-surface sensor S2, and an arm-retraction sensor S4. In other embodiments, one or more other components of the case sealer 10 (such as the base assembly 100 and / or the mast 190) include the one or both of the sensors S2 and S4.

[0027] The top-head-assembly frame 410 is formed from any suitable combination of solid or tubular members and / or plates fastened together. The first and second legs 310 and 320 of the top-head-assembly support 300 are attached to the top-head-assembly frame 410 in any suitable manner, such as via fasteners. The upper drive assembly 420 is supported by the top-head-assembly frame 410 and (along with the lower drive assembly described above) configured to move cases in the direction D. The upper drive assembly 420 includes an upper drive element 420a (or in other embodiments multiple upper drive elements) and a driven gear pulley 422 operably connected to the upper drive element to drive the upper drive element 420a. As described below, the upper-drive-actuating assembly 600 is operably connected to the driven gear pulley 422 and configured to drive the driven gear pulley 422.

[0028] The leading-surface sensor S2 includes a mechanical paddle switch (or any other suitable sensor, such as a proximity sensor) positioned at a front end of the top-head- assembly frame 410 and configured to detect when the leading surface of a case initially contacts (or is within a predetermined distance of) the top-head assembly 400. The leading-surface sensor S2 is communicatively connected to the controller 90 to send signals to the controller 90responsive to actuation (a case-detected signal) and de-actuation (a case-undetected signal) of the leading-surface sensor S2 (corresponding to the leading-surface sensor S2 detecting and no longer detecting the case and / or an object).

[0029] The arm-retraction sensor S4 includes a proximity sensor (or any other suitable sensor) configured to detect the presence of a case. Here, although not shown, the armretraction sensor S4 is positioned on the underside of the top-head-assembly frame 410 downstream of the case-entry sensor S3 so the arm-retraction sensor S4 can detect when a case reaches a particular position underneath the top-head assembly 400 (here, a position just before the case contacts the front rollers of the tape cartridges, as explained below). The arm -retraction sensor S4 is communicatively connected to the controller 90 to send signals to the controller 90 responsive to detecting the case (a case-detected signal) and no longer detecting the case (a case- undetected signal).

[0030] The top-head-actuating assembly 500 is operably connected to the top-head- assembly support 300 and the top-head assembly 400 and configured to move the top-head- assembly support 300 and the top-head assembly 400 vertically relative to the actuator support 200 and the base assembly 100. The top-head-actuating assembly 500 includes a top-head- assembly actuator 500a, a drive pulley 502, a connector 504, a first tension pulley 506, and a second tension pulley 508.

[0031] The top-head-assembly actuator 500a is mounted to the actuator support 200 — and here the connector 230 — in any suitable manner, such as via fasteners. The top-head- assembly actuator 500a is operably connected to the top-head-assembly support 300 and the tophead assembly 400 and configured to move the top-head-assembly support 300 and the top-head assembly 400 vertically relative to the actuator support 200 and the base assembly 100. Specifically, in this example embodiment, the top-head-assembly actuator 500a is operably connected to and configured to rotate the drive pulley 502. The drive pulley 502 drivingly engages the connector 504, which is a toothed belt in this example embodiment and is connected to the connector 330 of the top-head-assembly support 300 at one end and to the top-head assembly 400 at its other end. The tension pulleys 506 and 508 are mounted to the actuator support 200 and positioned on opposite sides of the drive pulley 502 so as to engage and maintain adequate tension in the connector 504.

[0032] As best shown in Figures 1 A and IB, the connector 230 of the actuator support 200 is positioned such that the top-head-assembly actuator 500a is above the lower surfaces of the upper drive element 420a of the top-head assembly 400 when the top-head assembly 400 is in its upper and its lower positions. This creates adequate space between the legs 210 and 220 of the actuator support 200 such that the operator can easily access the lower tape cartridge 1000a for tape replacement or cartridge removal, which speeds the process and reduces downtime.

[0033] The controller 90 is operably connected to the top-head-assembly actuator 500a to control vertical movement of the top-head-assembly support 300 and the top-head assembly 400. Specifically, the controller 90 controls the top-head-assembly actuator 500a to rotate the drive pulley 502 in one rotational direction (clockwise from the perspective shown in Figures 1 A and IB) to raise the top-head-assembly support 300 and the top-head assembly 400 relative to the base assembly 100 and in the opposite rotational direction (counterclockwise from the perspective shown in Figures 1 A and IB) to lower the top-head-assembly support 300 and the top-head assembly 400 relative to the base assembly 100.

[0034] This is merely one example configuration of the top-head-actuating assembly 500, and other suitable configurations may be employed. In certain embodiments, the top-head- actuating assembly includes a rack-and-pinion assembly in which a toothed rack extends between the top-head-assembly support and the top-head assembly and the top-head-assembly actuator is configured to drive a pinion gear meshed with the toothed rack to vertically move the top-head-assembly support and the top-head assembly. In other embodiments, the top-head- actuating assembly includes an electric linear actuator, a pneumatic actuator, or a hydraulic actuator connected to the top-head-assembly support or the top-head assembly and configured to vertically move the top-head-assembly support and the top-head assembly.

[0035] The upper-drive-actuating assembly 600 is operably connected to and configured to drive the driven gear pulley 422 of the top-head assembly 400. The upper-driveactuating assembly 600 includes an upper-drive actuator 620a, a drive pulley 622, an idler pulley 624, a connector 626, a first tension pulley 628, and a second tension pulley 630.

[0036] The upper-drive actuator 620a is mounted to the actuator support 200 — and here the connector 230 — in any suitable manner, such as via fasteners. The idler pulley 624 is mounted to the connector 330 of the top-head-assembly support 300. The upper-drive actuator620a is operably connected to and configured to drive the driven gear pulley 422. Specifically, in this example embodiment, the upper-drive actuator 620a is operably connected to and configured to rotate the drive pulley 622. The drive pulley 622 drivingly engages the connector 626, which is a toothed belt in this example embodiment and extends around the idler pulley 624 and the driven gear pulley 422. The tension pulleys 628 and 630 are mounted to the actuator support 200 and positioned on opposite sides of the drive pulley 502 so as to engage and maintain adequate tension in the connector 626.

[0037] The controller 90 is operably connected to the upper-drive actuator 620a to control movement of the upper drive element 420a of the upper drive assembly 420 of the tophead assembly 400. Specifically, the controller 90 controls upper-drive actuator 620a to rotate the drive pulley 622 to drive the connector 626, which in turn drives the driven gear pulley 422, which in turn drives the upper drive element 420a. In other embodiments, a chain-and-sprocket assembly is employed instead of the gear pulleys and toothed belt to operably connect the upperdrive actuator to the upper drive element. In further embodiments, toothless pulleys are employed with a friction belt to operably connect the upper-drive actuator to the upper drive element.

[0038] Since the upper-drive actuator 620a is mounted to the actuator support 200, the top-head assembly 400 of the present disclosure is lighter and easier to move than a top-head assembly that carries this actuator. A lighter top-head assembly requires less energy to move, which lowers energy costs and, therefore, operating costs.

[0039] The controller 90 is operably connected to: (1) the top-head actuator 500a and configured to control the top-head actuator 500a to control vertical movement of the tophead-assembly support 300 and the top-head assembly 400 responsive to signals received from the sensors S2, S3, and S5; and (2) the lower tape cartridge 1000a and the upper tape cartridge 1000b and configured to control the force-reduction functionality of these tape cartridges responsive to signals received from the arm-retraction sensor S4, as described in detail below in conjunction with Figures 5A-5H.

[0040] The lower tape cartridge 1000a is configured to apply tape to a leading surface, a bottom surface, and a trailing surface of the case, and the upper tape cartridge 1000b is configured to apply tape to the leading surface, a top surface, and the trailing surface of a case. Inthis example embodiment, the lower and upper tape cartridges are substantially the same and referred to in the accompanying description as the “tape cartridge.”

[0041] The tape cartridge 1000 includes a first mounting plate Ml that supports a front roller assembly 1100, a rear roller assembly 1200, a cutter assembly 1300, a tape-mounting assembly 1400, a tension-roller assembly 1500, a tape-cartridge-actuating assembly 1600, and a wipe-down element 1900. As best shown in Figure 5 A, a second mounting plate M2 is mounted to the first mounting plate Ml via multiple spacer shafts and fasteners (not labeled) to partially enclose certain elements of the front roller assembly 1100, the rear roller assembly 1200, the cutter assembly 1300, the tape-mounting assembly 1400, the tension-roller assembly 1500, the tape-cartridge-actuating assembly 1600, and the wipe-down element 1900 therebetween.

[0042] The front roller assembly 1100 includes a front roller arm 1110 and a front roller 1120. The front roller arm 1110 is pivotably mounted to the first mounting plate Ml via a front roller-arm-pivot shaft PSFRONT SO the front roller arm 1110 can pivot relative to the mounting plate Ml about an axis between a front roller arm extended position (Figures 5A-5C) and a front roller arm retracted position (Figure 5D). The front roller arm 1110 includes a front roller-mounting shaft 1120a, and the front roller 1120 is rotatably mounted to the front rollermounting shaft 1120a so the front roller 1120 can rotate relative to the front roller-mounting shaft 1120a.

[0043] The rear roller assembly 1200 includes a rear roller arm 1210 and a rear roller 1220. The rear roller arm 1210 is pivotably mounted to the first mounting plate Ml via a rear roller-arm-pivot shaft PSREAR SO the rear roller arm 1210 can pivot relative to the mounting plate Ml about an axis AREAR between a rear roller arm extended position (Figures 5A-5C) and a rear roller arm retracted position (Figure 5D). The rear roller arm 1210 includes a rear rollermounting shaft 1220a, and the rear roller 1220 is rotatably mounted to the rear roller-mounting shaft 1220a so the rear roller 1220 can rotate relative to the rear roller-mounting shaft 1220a.

[0044] A rigid first linking member 1020 is attached to and extends between the first roller arm 1110 and the second roller arm 1210. The first linking member 1020 links the front and rear roller assemblies 1100 and 1200 so: (1) moving the front roller arm 1110 from the front roller arm extended position to the front roller arm retracted position causes the first linking member 1020 to force the rear roller arm 1210 to move from the rear roller arm extended position to the rear roller arm retracted position (and vice-versa); and (2) moving the rear rollerarm 1210 from the rear roller arm extended position to the rear roller arm retracted position causes the first linking member 1020 to force the front roller arm 1110 to move from the front roller arm extended position to the front roller arm retracted position (and vice-versa).

[0045] The tape-cartridge-actuating assembly 1600 (Figure 2) includes a roller-arm- actuating assembly 1700 and a cutter-arm-actuating assembly 1800.

[0046] The roller-arm-actuating assembly 1700 is configured to move the linked front and rear roller arms 1110 and 1210 between their respective extended and retracted positions. As best shown in Figure 5G, in this example embodiment the roller-arm-actuating assembly 1700 includes a support plate 1702 and a roller-arm actuator 1710 pivotably attached to the support plate 1702 via a pin assembly 1703. The roller-arm actuator 1710 may be any suitable actuator, such as a motor or a pneumatic cylinder fed with pressurized gas and controlled by one or more valves.

[0047] The roller-arm actuator 1710 is operably connected to the front roller assembly 1100 to control movement of the front roller arm 1110 and the rear roller arm 1210 linked to the front roller arm 1110 between their respective extended and retracted positions. More specifically, the roller-arm actuator 1710 is coupled between the mounting plate M2 and the first roller arm assembly 1100 via attachment of the support plate 1702 to the mounting plate M2 and attachment of the roller-arm actuator 1710 to the shaft 1130 of the front roller assembly 1100.

[0048] The controller 90 is operably connected to the roller-arm actuator 1710 and configured to control the roller-arm actuator 1710 and therefore the positions of the front and rear roller arms 1110 and 1210.

[0049] As best shown in Figures 5E and 5F, the cutter assembly 1300 includes a cutter arm 1301, a cutting-device cover pivot shaft 1306, a cutter-arm-actuator-coupling element 1310, a cutting-device-mounting assembly 1320, a cutting device 1330 including a toothed blade (not labeled) configured to sever tape, a cutting-device cover 1340, a cutting-device pad 1350, and a rotation-control plate 1360.

[0050] The cutter arm 1301 includes a cylindrical surface 1301a that defines a cutter arm mounting opening. The cutter arm 1301 is pivotably mounted (via the cutter arm mounting opening) to the first mounting plate Ml via the front roller-arm-pivot shaft PSFRONT and bushings 1303a and 1303b so the cutter arm 1301 can pivot relative to the mounting plate Ml about theaxis between a cutter arm extended position (Figures 5A-5C) and a cutter arm retracted position (Figure 5D).

[0051] The cutter-arm-actuator-coupling element 1310 includes a support plate 1312 and a coupling shaft 1314 extending transversely from the support plate 1312. The support plate 1312 is fixedly attached to the cutter arm 1301 via fasteners.

[0052] The cutting-device-mounting assembly 1320 is fixedly mounted to the support arm 1301 (such as via welding) and is configured to removably receive the cutting device 1330. That is, the cutting-device-mounting assembly 1320 is configured so the cutting device can be removably mounted to the cutting-device-mounting assembly 1320. The cuttingdevice-mounting assembly 1320 is described in U.S. Patent No. 8,079,395, though any other suitable cutting-device-mounting assembly may be used to support the cutting device 1330.

[0053] The cutting-device cover 1340 includes a body 1342 and a finger 1344 extending from the body 1342. A pad 1350 is attached to the body 1342. The cutting-device cover 1340 is pivotably mounted to the support arm 1301 via mounting openings (not labeled) and the cutting-device cover pivot shaft 1306. Once attached, the cutting-device cover 1340 is pivotable about an axis relative to the cutter arm 1301 and the cutting-device-mounting assembly 1320 from front to back and back to front between a closed position and an open position. A cutting-device cover biasing element 1346, which includes a torsion spring in this example embodiment, biases the cutting-device cover 1340 to the closed position. When in the closed position, the cutting-device cover 1340 encloses the cutting device 1330 so the pad 1350 contacts the toothed blade of the cutting device 1330. When in the open position, the cutting-device cover 1340 exposes the cutting device 1330 and its toothed blade.

[0054] The cutting-device cover pivot shaft 1306 is also attached to the rotationcontrol plate 1360. The rotation-control plate 1360 includes a slot-defining surface 1362 that defines a slot. The surface 1362 acts as a guide (not shown) for a bushing that is attached to the mounting plate M2. The bushing provides lateral support for the cutter assembly 1300 to prevent the cutter assembly 1300 from moving toward or away from the mounting plates Ml and M2 and interfering with other components of the tape cartridge 1000 when in use.

[0055] The cutter-arm-actuating assembly 1800 is configured to move the cutter arm 1301 between its retracted position and its extended position. As best shown in Figure 6H, in this example embodiment the cutter-arm-actuating assembly 1800 includes a cutter-arm actuator1810. The cutter-arm actuator 1810 may be any suitable actuator, such as a motor or a pneumatic cylinder fed with pressurized gas and controlled by one or more valves.

[0056] The cutter-arm actuator 1810 is operably connected to the cutter assembly 1300 to control movement of the cutter arm 1301 from its retracted position to its extended position. More specifically, the cutter-arm actuator 1810 is coupled between the mounting plate Ml and the cutter assembly 1300 via attachment to the shaft 1610 and to the coupling shaft 1314 of the cutter-arm-actuator-coupling element 1310.

[0057] The controller 90 is operably connected to the cutter-arm actuator 1810 and configured to control the cutter-arm actuator 1810 and therefore the position of the cutter arm 1301.

[0058] The tape-mounting assembly 1400 includes a tape-mounting plate 1410 and a tape-core-mounting assembly 1420 rotatably mounted to the tape-mounting plate 1410. The tapecore-mounting assembly 1420 is further described in U.S. Patent No. 7,819,357 (though other tape core mounting assemblies may be used in other embodiments). A roll R of tape is mountable to the tape-core-mounting assembly 1420.

[0059] The tension-roller assembly 1500 includes several rollers (not labeled) rotatably disposed on shafts that are supported by the first mounting plate Ml. A free end of the roll R of tape mounted to the tape-core-mounting assembly 1420 is threadable through the rollers until the free end is adjacent the front roller 1120 of the front-roller assembly 1100 with its adhesive side facing outward in preparation for adhesion to a case. The tension-roller assembly 1500 is further described in U.S. Patent No. 7,937,905 (though other tension roller assemblies may be used in other embodiments).

[0060] The wipe-down element 1900 includes a base 1910 and one or more deformable elements 1920 connected to the base 1910. The base 1910 is fixedly mounted to and extends between the first and second mounting plates M l and M2 downstream of the rear roller assembly 1200. The wipe-down element 1900 is oriented so the deformable elements 1920 extend toward the roller 1220 when the rear roller arm 1210 is in the rear-roller-arm extended position. The deformable elements 1920 are rigid enough to return to their original shape when no force is applied to them yet compliant enough to deform when sufficient force is applied to them, such as when a case is forced against them as described below. In this exampleembodiment, the deformable elements 1920 are bristles, though they may be any suitable elements in other embodiments (such as foam or rubber elements).

[0061] The lower tape cartridge 1000a is removably mounted to the base assembly 100 and configured to apply tape to the leading surface, the bottom surface, and the trailing surface of the case. The upper tape cartridge 1000b is removably mounted to the top-head assembly 400 in any suitable manner and is configured to apply tape to a leading surface, a top surface, and a trailing surface of a case.

[0062] Operation of the case sealer 10 is now described in conjunction with Figures 6A-6I. Initially, the top-head assembly 400 and the top-head-assembly support 300 are at their initial lower positions; the side rails 114a and 114b are in their rest configuration; the front roller arm 1110, the rear roller arm 1210, and the cutter arm 1301 of the lower tape cartridge 1000a are in their respective extended positions; and the front roller arm 1110, the rear roller arm 1210, and the cutter arm 1301 of the upper tape cartridge 1000b are in their respective extended positions. The controller 90 controls the lower-drive-assembly actuator 118 and the upper-drive actuator 620a to drive the first and second lower drive elements 150a and 150b of the base assembly 100 and the upper drive element 420a of the top-head assembly 400, respectively.

[0063] The operator positions a case on the infeed table 112. The infeed-table sensor SI detects the presence of the case and in response sends a corresponding case-detected signal to the controller 90. Responsive to receiving that case-detected signal, the controller 90 controls the side-rail actuator 117 to move the side rails 114a and 114b from the rest configuration to the centering configuration so the side rails 114a and 114b move laterally inward to engage and center the case on the infeed table 112.

[0064] The operator then moves the case into contact with the leading-surface sensor S2, as shown in Figure 6B. This causes the leading-surface sensor S2 (via the case contacting and actuating the paddle switch of the leading-surface sensor S2) to detect the case and in response send a corresponding case-detected signal to the controller 90. Responsive to receiving the case-detected signal, the controller 90 controls the top-head-assembly actuator 500a to begin rotating the drive pulley 502 to raise the top-head-assembly support 300 and the top-head assembly 400. As the top-head-assembly support 300 and the top-head assembly 400 move upward, the leading-surface sensor S2 eventually stops detecting the case, as shown in Figure 6C. This indicates that the top-head assembly 400 has ascended above the top surface of the case.In response to no longer detecting the case, the leading-surface sensor S2 sends a corresponding case-undetected signal to the controller 90. Responsive to receiving that signal, the controller 90 controls the top-head-assembly actuator 500a to stop rotating the drive pulley 502 to maintain the height of the top-head-assembly support 300 and the top-head assembly 400.

[0065] Once the top-head assembly 400 ascends above the top surface of the case C, the operator moves the case C to a holding position partially beneath the top-head assembly 400 and atop the first and second lower drive elements 150a and 150b, at shown in Figure 6D, at which point the operator stops moving the case C. As the case C moves beneath the top-head assembly 400 and toward the holding position, the case-entry sensor S3 detects the presence of the case C beneath the top-head assembly and in response sends a corresponding case-detected signal to the controller 90. Responsive to receiving this signal, the controller 90 controls the tophead-assembly actuator 500a to begin rotating the drive pulley 502 to begin lowering the tophead-assembly support 300 and the top-head assembly 400, as shown in Figure 6E. Eventually, the upper drive element 420a of the upper drive assembly 420 of the top-head assembly 400 engage the top surface of the case C and joins the first and second lower drive elements 150a and 150b in moving the case C in the direction D, as shown in Figure 6F. The controller 90 controls the top-head-assembly actuator 500a to stop rotating the drive pulley 502 to maintain the height of the top-head-assembly support 300 and the top-head assembly 400.

[0066] The controller 90 receives a case-detected signal from the arm-retraction sensor S4 (indicating that the arm-retraction sensor S4 detected the case C) and in response controls the roller-arm actuators 1710 and the cutter-arm actuators 1810 of the lower and upper tape cartridges 1000a and 1000b to move their respective first and second roller arms 1110 and 1120 and cutter arms 1301 to their retracted positions. The leading surface of the case C contacts the front rollers 1120 as the front roller arms 1110 are moving to their retracted positions, which causes the tape positioned on the front rollers 1120 to adhere to the leading surface of the case C. When the front and rear roller arms 1110 and 1210 are in their retracted positions, the front and rear rollers 1120 and 1220 are positioned to apply enough pressure to the tape to adhere the tape to the top and bottom surfaces of the case C. When the cutter arms 1301 are in their retracted positions, the cutter arms 1301 do not contact the top or bottom surfaces of the case C (though in certain embodiments they may do so). The controller 90 controls the roller-arm actuators 1710 and the cutter-arm actuators 1810 to retain the front and rear roller arms 1110 and 1210 and thecutter arms 1301 in their respective retracted positions as the upper and lower drive assemblies move the case C past the tape cartridges 1000a and 1000b.

[0067] The case C eventually moves off of the infeed table 112, as shown in Figure 6G, at which point the infeed-table sensor SI stops detecting the case C and sends a corresponding case-undetected signal to the controller 90. Responsive to receiving that case- undetected signal, the controller 90 controls the side-rail actuator 117 to move the side rails 114a and 114b from the centering configuration to the rest configuration to make space on the infeed table 112 for the next case.

[0068] At some point, the case-exit sensor S5 detects the presence of the case C (though this may occur after the arm-retraction sensor S4 stops detecting the case depending on the length of the case) and sends a corresponding case-detected signal to the controller 90.

[0069] Once the arm-retraction sensor S4 stops detecting the case C (indicating that the case C has moved past the arm-retraction sensor S4), the arm-retraction sensor S4 sends a corresponding case-undetected signal to the controller 90. In response, the controller 90 controls the roller-arm actuators 1710 of the tape cartridges 1000a and 1000b to return the first and second roller arms 1110 and 1120 to their respective extended positions to apply tape to the trailing surface of the case C and controls the cutter-arm actuators 1810 of the tape cartridges 1000a and 1000b to return the cutter arms 1301 to their extended positions to cut the tape from the rolls. As this occurs, the fingers 1344 of the cutting-device covers 1340 contact the top and bottom surfaces of the case C so the cutting-device covers 1340 pivot to their open positions and expose the cutting devices 1330. Continued movement of the cutter arms 1301 brings the toothed blades of the cutting devices 1330 into contact with the tape and severs the tape from the respective rolls R. As the front and rear roller arms 1110 and 1210 move back to their extended positions, the rear roller arms 1210 move so the rear rollers 1220 contact the severed ends of the tape and apply the tape to the trailing surface of the case C to complete the taping process.

[0070] The upper and lower drive assemblies continue to move the case C until it exits from beneath the top-head assembly 400 onto the outfeed table 113, as shown in Figure 6H, at which point the case-exit sensor S5 stops detecting the case C and sends a corresponding case- undetected signal to the controller 90. In response, the controller 90 controls the top-head- assembly actuator 500a to drive the drive pulley 502 such that the top-head-assembly support 300 and the top-head assembly 400 descends back to its initial positions, as shown in Figure 61.

[0071] In some embodiments, the tape cartridge includes biasing elements that bias the roller arms and the cutter arm to their respective extended positions. The biasing elements eliminate the need for direct actuation of the roller arms and the cutter arm from their respective retracted positions to their respective extended positions.

[0072] In certain embodiments, the controller is separate from and in addition to the sensors. In other embodiments, the sensors function as their own controllers. For instance, in one embodiment, the retraction sensor is configured to directly control the cutter and roller arm actuators responsive to detecting the presence of and the absence of the case, the infeed-table sensor is configured to directly control the side rail actuator responsive to detecting the presence of and the absence of the case, and the leading-surface and top-surface sensors are configured to directly control the top head actuator responsive to detecting the presence of and the absence of the case (or contact with the case).

[0073] In various embodiments, the upper-drive actuator is supported by the tophead assembly and not the actuator support.

Claims

Claims1. A case sealer comprising: a frame; a top-head-assembly support; a top-head assembly configured to support a tape cartridge that is configured to support a tape roll, the top-head assembly connected to the top-head-assembly support and vertically movable with the top-head-assembly support relative to the frame; an actuator support; and a first actuator supported by the actuator support, wherein the first actuator is operably connected to the top-head-assembly support and the top-head-assembly to vertically move the top-head-assembly support and the top-head-assembly relative to the frame and the actuator support between a lower position and an upper position.

2. The case sealer of claim 1, wherein the first actuator is above the top-head assembly when the top-head assembly is in the lower position.

3. The case sealer of claim 2, wherein the first actuator is above the top-head assembly when the top-head assembly is in the upper position.

4. The case sealer of claim 1, wherein the first actuator comprises an electric actuator.

5. The case sealer of claim 4, further comprising a drive pulley and a connector drivingly engaged by the drive pulley and connected to and extending between the top-head- assembly support and the top-head assembly, wherein the first actuator is operably connected to the drive pulley to rotate the drive pully in a first rotational direction to raise the top-head- assembly support and the top-head assembly and a second rotational direction opposite the first rotational direction to lower the top-head-assembly support and the top-head assembly.

6. The case sealer of claim 1, wherein the actuator support comprises a linear bearing, wherein the top-head-assembly support comprises a leg extending through the linear bearing.

7. The case sealer of claim 1, further comprising a second actuator supported by the actuator support, wherein the top-head assembly further comprises an upper drive element, wherein the second actuator is operably connected to the upper drive element to drive the upper drive element.

8. The case sealer of claim 7, wherein the top-head-assembly support and the tophead assembly are vertically movable relative to the second actuator.

9. The case sealer of claim 7, wherein the upper drive element comprises an endless belt.

10. The case sealer of claim 7, further comprising a drive pulley, a connector drivingly engaged by the drive pulley, and an idler pulley drivingly engaged by the connector, wherein the top-head assembly further comprises a driven pulley drivingly engaged by the connector and operably connected to the upper drive element to drive the upper drive element.

11. The case sealer of claim 10, wherein the idler pulley is supported by and vertically movable with the top-head-assembly support.

12. The case sealer of claim 7, wherein the first and second actuators are above the top-head assembly when the top-head assembly is in the lower position.

13. The case sealer of claim 12, wherein the first and second actuators are above the top-head assembly when the top-head assembly is in the upper position.

14. The case sealer of claim 7, wherein the first and second actuators comprise electric actuators.

15. The case sealer of claim 14, further comprising a first drive pulley and a first connector drivingly engaged by the first drive pulley and connected to and extending between the top-head-assembly support and the top-head assembly, wherein the first actuator is operably connected to the first drive pulley to rotate the first drive pully in a first rotational direction to raise the top-head-assembly support and the top-head assembly and a second rotational direction opposite the first rotational direction to lower the top-head-assembly support and the top-head assembly.

16. The case sealer of claim 15, wherein the actuator support comprises a first linear bearing and a second linear bearing, wherein the top-head-assembly support comprises: first and second legs extending through the first and second linear bearings, respectively; and a connector that connects the first and second legs.

17. The case sealer of claim 16, further comprising a second drive pulley, a second connector drivingly engaged by the second drive pulley, and an idler pulley drivingly engaged by the second connector, wherein the top-head assembly further comprises a driven pulley drivingly engaged by the second toothed belt and operably connected to the upper drive element to drive the upper drive element.

18. The case sealer of claim 17, wherein the idler pulley is supported by the connector of the top-head-assembly support.

19. The case sealer of claim 1, wherein the first actuator comprises a pneumatic cylinder.

20. The case-sealer of claim 1, further comprising: a lower drive element supported by the frame below the top-head assembly; and a lower-drive-element actuator operably connected to the lower drive element to drive the lower drive element, wherein the first actuator is positioned above the lower drive element.

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