Adaptive carton sealing machine

Abstract

Various embodiments of the present disclosure provide a case sealer including a frame, a top head including a tape cartridge configured to support a tape roll, a top-head-actuating assembly operably connected to the top head, and a controller. The top head is vertically movable relative to the frame. The controller is configured to: control the top-head-actuating assembly to move the top head to a height based on a height of a case; control the top-head-actuating assembly to maintain the top head at the height; and, responsive to a switching condition being met, control the top-head-actuating assembly to stop maintaining the top head at the height and start exerting a resistive force on the top head such that the top head lowers into engagement with the case.

Description

ADAPTIVE CARTON SEALING MACHINEPriority

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 622,659, filed January 19, 2024, 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. As the case moves beneath the top head, the top head exerts a downward force on the top surface of the case that is equal to the difference between the weight of the top head and the resistive force. This downward force enables semi-automatic random case sealers to adjust to and adequately seal overfilled cases without j amming.

[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. Automatic random case sealers offer a higher throughput than semi-automatic random case sealers in part because they adjust to the height of the case before the case reaches the top head, meaning the case does not have to sit idle while the top head ascends to make room for the case and then descends atop the case. But since automatic random case sealers fix the height of the top head throughout the entire sealing process and do not exert a downward force on the case, they cannot adjust to and seal overfilled cases.Summary

[0006] Various embodiments of the present disclosure provide a case sealer including a frame, a top head including a tape cartridge configured to support a tape roll, a tophead-actuating assembly operably connected to the top head, and a controller. The top head is vertically movable relative to the frame. The controller is configured to: control the top-head- actuating assembly to move the top head to a height based on a height of a case; control the tophead-actuating assembly to maintain the top head at the height; and, responsive to a switching condition being met, control the top-head-actuating assembly to stop maintaining the top head at the height and start exerting a resistive force on the top head such that the top head lowers into engagement with the case.Brief Description of the Figures

[0007] Figure 1 is a perspective view of one example embodiment of a case sealer of the present disclosure.

[0008] Figure 2 is a perspective view of part of the case sealer of Figure 1 with the cover of the first mast removed.

[0009] Figure 3 is a block diagram showing certain components of the case sealer of Figure 1.

[0010] Figure 4 is a perspective view of the top head of the case sealer of Figure 1.

[0011] Figures 5A-5H are various views of the tape cartridge of the case sealer ofFigure 1 and its components.

[0012] Figures 6A-6F are side views of the case sealer of Figure 1 sealing a case. The first mast is removed for clarity.

[0013] Figure 7 is a flowchart of one example method of operating the case sealer of Figure 1.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] Figure 1-6F show one example embodiment of an automatic random case sealer 10 of the present disclosure and components thereof. The case scaler 10 includes a base assembly 100, a first mast 200, a second mast 250, a top head 300, a top-head-actuating assembly 400, a controller 90, a lower tape cartridge 1000a, and an upper tape cartridge 1000b. As shown in Figure 3, the case sealer 10 also includes multiple actuating assemblies and actuators operably connected to and configured to control movement of certain components of the case sealer 10; multiple sensors S1-S4; 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 controller 90 is 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) or combination of controllers 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, such as to carry out the method 2000 shown in Figure 7 and described below.

[0017] The base assembly 100 is configured to align cases in preparation for sealing and to — along with the top-head assembly 300 — move the cases through the case sealer 10. The base assembly 100 supports the lower tape cartridge 1000a and the first and second masts 200 and 250, which in turn support the top head 300 that includes the upper tape cartridge 1000b. The base assembly 100, which is best shown in Figure 1, 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 incoming cases are directed 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 111 is configured to support various components of the case sealer 10 and is formed from any suitable combination of solid and / or tubular membersand / or plates fastened together. The infeed table 112 is mounted to the base-assembly frame 11 1 adjacent the infeed end IN of the case sealer 10. The infeed table 112 includes multiple driven rollers for conveying the case toward the top head 300. The infeed table 112 includes an infeedtable sensor SI, 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 generally 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 generally parallel to a direction of travel D of a case through the case sealer 10 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 1) in which the side rails are positioned at or near the lateral extents of the infeed table 112 to enable the case to be fed 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 111 and (along with an upper drive assembly 320, described below) configured to move cases in the direction D. The lower drive assembly includes first and second lower drive elements (though itmay include only one drive element or more than two drive elements in other embodiments) and a lower-drive-assembly actuator 118 operably connected to the first and second lower drive elements and configured to drive the first and second lower drive elements to (along with the upper drive assembly 320) move cases through the case sealer 10. In this example embodiment, the lower-drive-assembly actuator 118 includes an electric motor that is operably connected to the first and second lower drive elements — which include endless belts in this example embodiment — via one or more other components, such as sprockets, gearing, screws, tensioning elements, and / or a chain. The lower-drive-assembly actuator may include any other suitable actuator in other embodiments. The first and second lower drive elements and may include any other suitable component or components, such as rollers, in other embodiments. The controller 90 is operably connected to the lower-drive-assembly actuator 118 to control operation of the lower-drive-assembly actuator 118.

[0021] The lower drive assembly supports a case-entry sensor S2 downstream of the infeed table 112 and beneath the top head 300 so the case-entry sensor S2 can detect when a case enters the area below the top head 300. As used herein, “downstream” means in the direction of travel D, and “upstream” means the direction opposite the direction of travel D. The case-entry sensor S2 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 S2 is supported by one of the masts or the top head. The case-entry sensor S2 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 S4 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 S4 is positioned near the outfeed table 113 (downstream of the case-entry and retraction sensors S2 and S3 described below) so the case-exit sensor S4 can detect when a case exits from beneath the top head 300. The case-exit 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).

[0023] The first and second masts 200 and 250, which are best shown in Figures 1 and 2, are attached to the base assembly 100 and configured to support and guide the verticalmovement of the top head 300 relative to the base assembly 100. The first mast 200 includes a cover 205, a cylindrical first rail 210, a cylindrical second rail 220, and a carriage 230. The cover 205 defines an enclosure in which the first and second rails 210 and 220 are mounted substantially parallel to one another and oriented substantially vertically. The carriage 230 is slidably mounted to the first and second rails 210 and 220 such that the carriage 230 is vertically movable along the rails relative to the base assembly 100. The second mast 250 is substantially similar to the first mast 200 and not separately described. These are merely example mast configurations, and they may be configured in any other suitable manner(s).

[0024] The top head 300, which is best shown in Figure 4, is movably supported by the first and second masts 200 and 250 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 300 includes a top-head frame 310, an upper drive assembly 320, and a retraction sensor S3. In other embodiments, one or more other components of the case sealer 10 (such as the base assembly 100 and / or one of the masts 200 and 250) includes the retraction sensor S3.

[0025] The top-head frame 310 is mounted to the slidable carriages of the first and second masts 200 and 250 and supports the other components of the top head 300. The top-head frame 310 is formed from any suitable combination of solid or tubular members and / or plates fastened together. The top-head frame 310 includes laterally extending first and second mounting arms 312 and 314 that are respectively connected to the slidable carriages of the first and second masts 200 and 250.

[0026] The upper drive assembly 320 is supported by the top-head frame 310 and (along with the lower drive assembly described above) configured to move cases in the direction D. The upper drive assembly 320 includes an upper drive element (or in other embodiments multiple upper drive elements) and an upper-drive-assembly actuator 322 operably connected to the upper drive element to drive the upper drive element to (along with the lower drive assembly) move cases through the case sealer 10. In this example embodiment, the upper-drive-assembly actuator 322 includes a motor that is operably connected to the upper drive element — which includes an endless belt in this example embodiment — via one or more other components, such as sprockets, gearing, screws, tensioning elements, and / or a chain. The upper-drive-assembly actuator 322 may include any other suitable actuator in other embodiments. The upper driveelement may include any other suitable component or components, such as rollers, in other embodiments. The controller 90 is operably connected to the upper-drive-assembly actuator 322 to control operation of the upper-drive-assembly actuator 322.

[0027] The top-head-actuating assembly 400 is operably connected to the top head 300 and configured to vertically move the top head 300 under control of the controller 90. More specifically, the controller 90 is configured to control the top-head-actuating assembly 400 to: (1) in preparation to seal an incoming case, move the top head 300 to a height slightly above the upper surface of the case and maintain the top head 300 at that height until the case is beneath the top head 300; and (2) after the case reaches and has moved beneath the top head 300, stop maintaining the top head 300 at the height and start exerting a resistive force on the top head 300 that is less than the weight of the top head 300 (which includes the weight of the upper tape cartridge and the tape roll mounted to the upper tape cartridge) so the top head 300 lowers into engagement with the case and exerts a downward force on the case as the case moves beneath the top head 300. In this illustrated example embodiment, the top-head-actuating assembly 400 includes a first actuator 410, a drive pulley 412, a driven pulley 414, a connector 416, and a second actuator 420.

[0028] The first actuator 410 includes an electric motor — and in particular a rotary servo motor — in this example embodiment. The first actuator 410 is mounted within the enclosure of the first mast 200 and drivingly engages the drive pulley 412, which is positioned substantially within the enclosure. The driven pulley 414 is positioned substantially within the enclosure 205 near the end opposite the drive pulley 412. The connector 416 — a toothed belt in this example embodiment — extends around and operably connects the drive pulley 412 and the driven pulley 414. The second mounting arm 314 of the top-head frame 310 of the top head 300 is fixedly connected to the connector 416 between the drive pulley 412 and the driven pulley 414. Accordingly, that when the first actuator 410 rotates the drive pulley 412, the drive pulley 412 causes the connector 416 and the top head 300 to move. For instance, from the perspective shown in Figure 2, rotation of the drive pulley 412 clockwise causes the top head 300 to descend, while rotation of the drive pulley 412 counter-clockwise causes the top head 300 to ascend. Accordingly, the first actuator 410 is operably connected to the top head 300 (via the drive pulley 412 and the connector 416) and configured to control the vertical movement of the top head 300. The first actuator may be any other suitable type of actuator in other embodiments.

[0029] The controller 90 is operably connected to the first actuator 410 and configured to control the first actuator 410 to operate in accordance with one of multiple different operating modes. For instance, the controller 90 is configured to, when the first actuator 410 is in a position mode, control the first actuator 410 to move the top head 300 to a particular position (e.g., a height) and to maintain the top head 300 at that position. The controller is configured to control the first actuator 410 to, when the first actuator 410 is in a force mode, exert a substantially constant first resistive force on the top head 300 to partially counteract gravity acting on the top head 300.

[0030] The second actuator 420 includes a pneumatic actuator — and in particular a pneumatic cylinder fed with pressurized gas and controlled by one or more valves — in this example embodiment. The second actuator 420 is positioned substantially within the enclosure and mounted between the carriage 230 and the base assembly 100. In this example embodiment, the second actuator 420 is configured to exert a substantially constant second resistive force on the top head 300 (via the carriage 230) to partially counteract gravity acting on the top head 300. The controller 90 is operably connected to the second actuator 420 and configured to control the second actuator 420, such as by controlling the valves that control the flow of pressurized air into the second actuator 420. The second actuator may be any other suitable type of actuator in other embodiments.

[0031] The retraction sensor S3 includes a proximity sensor (or any other suitable sensor) configured to detect the presence of a case. Here, although not shown, the retraction sensor S3 is positioned on the underside of the top-head frame 310 so the retraction sensor S3 can detect when a case reaches a particular position underneath the top head 300 (here, a position just before the case contacts the front rollers of the tape cartridges, as explained below). The retraction 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).

[0032] The controller 90 is operably connected to: (1) the top-head-actuating assembly 400 and configured to control the top-head-actuating assembly 400 to control vertical movement of the top head 300 responsive to signals received from the sensors S2 and S4; and (2) the lower tape cartridge 1000a and the upper tape cartridge 1000b and configured to control theforce-reduction functionality of these tape cartridges responsive to signals received from the retraction sensor S3, as described in detail below in conjunction with Figures 5A-5H.

[0033] The lower tape cartridge 1000a is configured to apply tape to a leading surface, a bottom surface, and a trailing surface of the case, and the upper tape cartridge 1000b is configured to apply tape to the leading surface, a top surface, and the trailing surface of a case. In this example embodiment, the lower and upper tape cartridges are identical and referred to in the accompanying description as the “tape cartridge.”

[0034] 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.

[0035] 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.

[0036] 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.

[0037] A rigid first linking member 1020 is attached to and extends between the first roller arm 1110 and the second roller arm 1210. The first linking member 1020 links the front and rear roller assemblies 1100 and 1200 so: (1) moving the front roller arm 1110 from the front roller arm extended position to the front roller arm retracted position causes the first linking member 1020 to force the rear roller arm 1210 to move from the rear roller arm extended position to the rear roller arm retracted position (and vice-versa); and (2) moving the rear roller arm 1210 from the rear roller arm extended position to the rear roller arm retracted position causes the first linking member 1020 to force the front roller arm 1110 to move from the front roller arm extended position to the front roller arm retracted position (and vice-versa).

[0038] The tape-cartridge-actuating assembly 1600 (Figure 2) includes a roller-arm- actuating assembly 1700 and a cutter-arm-actuating assembly 1800.

[0039] The roller-arm-actuating assembly 1700 is configured to move the linked front and rear roller arms 1110 and 1210 between their respective extended and retracted positions. As best shown in Figure 6G, in this example embodiment the roller-arm-actuating assembly 1700 includes a support plate 1702 and a roller-arm actuator 1710 pivotably attached to the support plate 1702 via a pin assembly 1703. The roller-arm actuator 1710 may be any suitable actuator, such as a motor or a pneumatic cylinder fed with pressurized gas and controlled by one or more valves.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] The cutter arm 1301 includes a cylindrical surface 1301a that defines a cutter arm mounting opening. The cutter arm 1301 is pivotably mounted (via the cutter arm mounting opening) to the first mounting plate Ml via the front roller-arm-pivot shaft PSFRONT and bushings 1303a and 1303b so the cutter arm 1301 can pivot relative to the mounting plate Ml about the axis between a cutter arm extended position (Figures 5A-5C) and a cutter arm retracted position (Figure 5D).

[0044] 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.

[0045] The cutting-device-mounting assembly 1320 is fixedly mounted to the support arm 1301 (such as via welding) and is configured to removably receive the cutting device 1330. That is, the cutting-device-mounting assembly 1320 is configured so the cutting device can be removably mounted to the cutting-device-mounting assembly 1320. The cutting- device-mounting assembly 1320 is described in U.S. Patent No. 8,079,395, though any other suitable cutting-device-mounting assembly may be used to support the cutting device 1330.

[0046] The cutting-device cover 1340 includes a body 1342 and a finger 1344 extending from the body 1342. A pad 1350 is attached to the body 1342. The cutting-device cover 1340 is pivotably mounted to the support arm 1301 via mounting openings (not labeled) and the cutting-device cover pivot shaft 1306. Once attached, the cutting-device cover 1340 is pivotable about an axis relative to the cutter arm 1301 and the cutting-device-mounting assembly 1320 from front to back and back to front between a closed position and an open position. A cutting-device cover biasing element 1346, which includes a torsion spring in this example embodiment, biases the cutting-device cover 1340 to the closed position. When in the closed position, the cutting-device cover 1340 generally encloses the cutting device 1330 so the pad 1350 contacts the toothed blade of the cutting device 1330. When in the open position, the cutting-device cover 1340 exposes the cutting device 1330 and its toothed blade.

[0047] The cutting-device cover pivot shaft 1306 is also attached to the rotationcontrol plate 1360. The rotation-control plate 1360 includes a slot-defining surface 1362 that defines a slot. The surface 1362 acts as a guide (not shown) for a bushing that is attached to themounting plate M2. The bushing provides lateral support for the cutter assembly 1300 to generally prevent the cutter assembly 1300 from moving toward or away from the mounting plates Ml and M2 and interfering with other components of the tape cartridge 1000 when in use.

[0048] 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 5H, in this example embodiment the cutter-arm-actuating assembly 1800 includes a cutter-arm actuator 1810. The cutter-arm actuator 1810 may be any suitable actuator, such as a motor or a pneumatic cylinder fed with pressurized gas and controlled by one or more valves.

[0049] 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.

[0050] 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.

[0051] The tape-mounting assembly 1400 includes a tape-mounting plate 1410 and a tape-core-mounting assembly 1420 rotatably mounted to the tape-mounting plate 1410. The tape- core-mounting assembly 1420 is further described in U.S. Patent No. 7,819,357 (though other tape core mounting assemblies may be used in other embodiments). A roll R of tape is mountable to the tape-core-mounting assembly 1420.

[0052] 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).

[0053] The wipe-down element 1900 includes a base 1910 and one or more deformable elements 1920 connected to the base 1910. The base 1910 is fixedly mounted to and extends between the first and second mounting plates Ml and M2 downstream of the rear rollerassembly 1200. The wipe-down element 1900 is oriented so the deformable elements 1920 extend toward the roller 1220 when the rear roller arm 1210 is in the rcar-roller-arm extended position. The deformable elements 1920 are rigid enough to return to their original shape when no force is applied to them yet compliant enough to deform when sufficient force is applied to them, such as when a case is forced against them as described below. In this example embodiment, the deformable elements 1920 are bristles, though they may be any suitable elements in other embodiments (such as foam or rubber elements).

[0054] 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 300 in any suitable manner and is configured to apply tape to a leading surface, a top surface, and a trailing surface of a case.

[0055] Figure 7 is a flowchart detailing a method of operating a case sealer 2000 to seal a case. The method 2000 begins by vertically moving a top head including a tape cartridge to a height that is based on a height of a case, as block 2010 indicates. The method 2000 continues by maintaining the top head at the height, as block 2020 indicates. The method 2000 continues by, responsive to a first switching condition being met, stop maintaining the top head at the height and start exerting a resistive force on the top head that is less than a weight of the top head (including the weight of the tape cartridge and tape roll mounted thereto) such that the top head lowers into engagement with the case, as block 230 indicates. The method 2000 continues by moving the case beneath the top head and past the tape cartridge such that tape from a tape supply of the tape cartridge is applied to the case, as block 2040 indicates. The method 2000 concludes by, responsive to a second switching condition being met, stop exerting the resistive force on the top head and resume maintaining the top head at the height, as block 2050 indicates.

[0056] Operation of the case sealer 10 in accordance with the method 2000 is now described in conjunction with Figures 6A-6F. Initially, the top head 300 is at its lower position; the side rails 114a and 114b are in their rest configuration; the front roller arm 1110, the rear roller arm 1210, and the cutter arm 1301 of the lower tape cartridge 1000a are in their respective extended positions; and the front roller arm 1110, the rear roller arm 1210, and the cutter arm90 controls the lower-drive-assembly actuator 1 18 and the upper-drive-assembly actuator 422 to drive the first and second lower drive elements of the base assembly 100 and the upper drive element of the top head 300, respectively. The controller 90 controls the second actuator 420 to apply the second resistive force to the top head 300. This reduces the load experienced by the first actuator 410 during operation.

[0057] As shown in Figure 6A, a case C on a roller conveyor is conveyed toward the case sealer 10. Before the case C reaches the top head 300, the controller 90 controls the first actuator 410 to raise the top head to a height. As shown in Figure 6B, the height is determined such that when the top head 300 is at the height the upper drive elements of the top head 300 are slightly above the upper surface of the case C. This provides the case C adequate space to enter the case sealer 10 beneath the top head 300. In this example embodiment, the controller 90 is communicatively connected to an external device — such as a central controller of the packaging line including the case sealer 10 — and configured to receive data representing the height from that external device (or to receive data representing the height of the case C from that external device and to determine the height based on the height of the case C). In other embodiments, the case sealer includes a height sensor configured to detect the height of the case to enable the controller to determine the height. The controller 90 controls the first actuator 410 to maintain the top head 300 at the height until a first switching condition is met. In this example embodiment, the first switching condition is met when the case-entry sensor S2 detects the case C.

[0058] Once the case C reaches on the infeed table 112, as shown in Figure 6B, the infeed-table sensor S 1 detects the presence of the case and in response sends a corresponding case-detected signal to the controller 90. Responsive to receiving that case-detected signal, the controller 90 controls the side-rail actuator 117 to move the side rails 114a and 114b from the rest configuration to the centering configuration so the side rails 114a and 114b move laterally inward to engage and center the case on the infeed table 112.

[0059] After centering, the case C continues moving and enters the area beneath the top head 300, as shown in Figure 6C. As the case C moves beneath the top head 300, the caseentry sensor S2 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 this occurring — and thus responsive to the first switching condition being met — the controller 90 controls thefirst actuator 410 to stop maintaining the top head 300 at the height and to start exerting a first resistive force on the top head 300. The first resistive force exerted by the first actuator 410 and the second resistive force exerted by the second actuator 420 collectively form a resistive force that the top-head-actuating assembly 400 exerts on the top head 300 to partially counteract gravity. In other words, the resistive force is less than the weight of the top head 300 (including the weight of the tape cartridge and tape roll mounted thereto) such that the top head 300 descends. Eventually, the upper drive elements of the upper drive assembly 320 of the top head 300 engage the top surface of the case C and join the first and second lower drive elements in moving the case C in the direction D, as shown in Figure 6C. The top head 300 exerts a downward force on the case C, which is equal to the difference between the weight of the top head 300 (including the weight of the tape cartridge and tape roll mounted thereto) and the resistive force exerted by the top-head-actuating assembly 400. This downward force enables adequate sealing of overfilled cases. The controller 90 continues to control the top-head- actuating assembly 400 to exert the resistive force on the top head 300 until a second switching condition is met. In this example embodiment, the second switching condition is met when the case-exit sensor S4 stops detecting the case C.

[0060] The controller 90 receives a case-detected signal from the retraction sensor S3 (indicating that the retraction sensor S3 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 the cutter arms 1301 in their respective retracted positions as the upper and lower drive assemblies move the case C past the tape cartridges 1000a and 1000b.

[0061] The case C eventually moves off of the infeed table 1 12, as shown in Figure 6D, 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.

[0062] At some point, the case-exit sensor S4 detects the presence of the case C (though this may occur after the retraction sensor S3 stops detecting the case depending on the length of the case) and sends a corresponding case-detected signal to the controller 90.

[0063] Once the retraction sensor S3 stops detecting the case C (indicating that the case C has moved past the retraction sensor S3), the retraction sensor S3 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.

[0064] The upper and lower drive assemblies continue to move the case C until it exits from beneath the top head 300 onto the outfeed table 113, as shown in Figure 6E, at which point the case-exit sensor S4 stops detecting the case C and sends a corresponding case- undetected signal to the controller 90. Responsive to this occurring — and thus responsive to the second switching condition being met — the controller 90 controls the first actuator 410 to stop exerting the first resistive force on the top head 300 and to resume maintaining the top head 300 at the height, as shown in Figure 6F.

[0065] The case sealer and method of operating the case sealer of the present disclosure therefore provides high throughput while also adequately sealing overfilled cases.

[0066] In other embodiments, the top-head-actuating assembly includes a clutch having an engaged state and a disengaged state. In these embodiments, the first top-head actuator is operably connected to the top head and thus configured to vertically move the top head when the clutch is in the engaged state and is not operably connected to the top head and thus not configured to vertically move the top head when in the disengaged state. The controller is configured to switch the clutch from the engaged state to the disengaged state. In these embodiments, the controller is configured to do so responsive to the first switching condition being met. For instance, with the clutch in the engaged state, the controller controls the first actuator to vertically move the top head to a height and to maintain the top head at that height in preparation for sealing a case. Meanwhile, the controller controls the second actuator to exert the resistive force on the top head. Responsive to the first switching condition being met, the controller switches the clutch to the disengaged state while the second actuator continues to exert the resistive force on the top head. This causes the top head to descend into engagement with the case. Once the case has been sealed and responsive to the second switching condition has been met, the controller is configured to switch the clutch back to the engaged state to enable the controller to again control the vertical position of the top head using the first actuator.

[0067] In certain embodiments, the top-head-actuating assembly include multiple first actuators, such as multiple electric motors, configured to operate together to move the tophead assembly. In various embodiments, the top-head-actuating assembly includes multiple second actuators, such as multiple pneumatic cylinders, configured to operate together to apply the second resistive force to the top head.

[0068] In various embodiments, the top-head-actuating assembly includes one or more electric actuators configured to position the top head and exert the resistive force on the top head (under control of the controller) and does not include any pneumatic actuators. For instance, in certain such embodiments, the top-head-actuating assembly includes two electric linear motors. In these embodiments, the controller is configured to control the linear motors to move the top head to and maintain the top head at a height and, in response to the first switching condition being met, control the linear motors to stop maintaining the top head at the height and start exerting the resistive force on the top head.

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

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

[0071] In other embodiments, the top-head-actuating assembly includes a shock absorber, such as a gas spring, instead of a the second actuator.

Claims

Claims1. A case sealer comprising: a frame; a top head including a tape cartridge configured to support a tape roll, wherein the top head is vertically movable relative to the frame; a top-head-actuating assembly operably connected to the top head; and a controller configured to: control the top-head-actuating assembly to move the top head to a height and maintain the top head at the height, wherein the height is based on a height of a case; and responsive to a switching condition being met, control the top-head-actuating assembly to stop maintaining the top head at the height and to exert a resistive force on the top head such that the top head lowers into engagement with the case.

2. The case sealer of claim 1, wherein the top-head-actuating assembly comprises at least one first top-head actuator and at least one second top-head actuator.

3. The case sealer of claim 2, wherein the controller is configured to: control the at least one first top-head actuator to move the top head to the height and to maintain the top head at the height; and responsive to the switching condition being met, control the at least one first top-head actuator to stop maintaining the top head at the height and control the at least one first top-head actuator and the at least one second top-head actuator to exert the resistive force on the top head such that the top head lowers into engagement with the case.

4. The case sealer of claim 3, wherein each of the at least one first top-head actuator comprises an electric actuator and each of the at least one second top-head actuator comprises a pneumatic actuator.

5. The case sealer of claim 4, wherein each of the at least one first top-head actuator comprises one or more motors and each of the at least one second top-head actuator comprises one or more pneumatic cylinders.

6. The case sealer of claim 5, wherein the controller is configured to, responsive to the switching condition being met, control the at least one first top-head actuator to exert a first resistive force on the top head; wherein the at least one second top-head actuator is configured to exert a second resistive force on the top head; and wherein the resistive force is equal to a sum of the first resistive force and the second resistive force.

7. The case sealer of claim 6, wherein the switching condition is met responsive to a case-position sensor detecting the case.

8. The case sealer of claim 7, wherein the case-position sensor is configured to detect the case beneath the top head.

9. The case sealer of claim 5, further comprising a clutch having an engaged state and a disengaged state, wherein the at least one first top-head actuator is operably connected to the top head when the clutch is in the engaged state and not operably connected to the top head when in the disengaged state, wherein the controller is configured to switch the clutch from the engaged state to the disengaged state responsive to the switching condition being met.

10. The case sealer of claim 9, wherein the at least one second top-head actuator is configured to exert the resistive force on the top head.

11. The case sealer of claim 10, wherein the switching condition is met responsive to a case-position sensor detecting the case.

12. The case sealer of claim 11, wherein the case-position sensor is configured to detect the case beneath the top head.

13. The case sealer of claim 5, further comprising: a drive pulley driven by the motor; a driven pulley; anda connector connecting the drive pulley and the driven pulley, wherein the connector is driven by the drive pulley and drives the drive pulley, wherein the top head is connected to and movable with the connector.

14. The case sealer of claim 1, wherein the top-head-actuating assembly comprises at least one top-head actuator, wherein the controller is configured to: control the at least one top-head actuator to move the top head to the height and maintain the top head at the height; and responsive to the switching condition being met, control the at least one top-head actuator to stop maintaining the top head at the height and to exert the resistive force on the top head such that the top head lowers into engagement with the case.

15. The case sealer of claim 14, wherein each of the at least one top-head actuator comprises an electric actuator.

16. The case sealer of claim 15, wherein each of the at least one top-head actuator comprises one or more motors.

17. The case sealer of claim 14, wherein the switching condition is met responsive to a case-position sensor detecting the case.

18. The case sealer of claim 17, wherein the case-position sensor is configured to detect the case beneath the top head.

19. The case sealer of claim 1, wherein the switching condition is met responsive to a case-position sensor detecting the case.

20. The case sealer of claim 19, wherein the case-position sensor is configured to detect the case beneath the top head.

21. The case sealer of claim 1, wherein the controller is further configured to determine the height based on the height of the case.

22. The case sealer of claim 21 , wherein the controller is further configured to receive data representing the height of the case.

23. The case sealer of claim 21, further comprising a case-height sensor configured to sense the height of the case.

24. The case sealer of claim 1, wherein the controller is further configured to receive data representing the height.

25. The case sealer of claim 1, wherein the switching condition comprises a first switching condition, wherein the controller is further configured to, responsive to a second switching condition being met, control the top-head-actuating assembly to stop exerting the resistive force on the top head and resume maintaining the top head at the height.

26. The case sealer of claim 25, wherein the first switching condition is met responsive to a first sensor detecting the case beneath the top head, wherein the second switching condition is met responsive to a second sensor detecting the case exiting from beneath the top head.

27. A method of operating a case sealer, the method comprising: moving a top head including a tape cartridge supporting a tape roll to a height, wherein the height is based on a height of a case; maintaining the top head at the height; determining that a switching condition has been met; and responsive to determining that the switching condition has been met: stop maintaining the top head at the height; and exerting a resistive force on the top head such that the top head lowers into engagement with the case.

28. The method of claim 27, wherein: moving the top head to the height comprises controlling a top-head-actuating assembly to move the top head to the height;maintaining the top head at the designated height comprises controlling the top-head- actuating assembly to maintain the top head at the height; and stop maintaining the top head at the height and exerting the resistive force on the top head comprises controlling the top-head-actuating assembly to stop maintaining the top head at the height and to exert the resistive force on the top head.

29. The method of claim 28, wherein: moving the top head to the height comprises controlling at least one first top-head actuator to move the top head to the height; maintaining the top head at the height comprises controlling the at least one first top-head actuator to maintain the top head at the height; stop maintaining the top head at the height comprises controlling the at least one first tophead actuator to stop maintaining the top head at the height; and exerting the resistive force on the top head comprises controlling the at least one first tophead actuator and at least one second top-head actuator to exert the resistive force on the top head.

30. The method of claim 29, further comprising: responsive to determining that the switching condition has been met, controlling the at least one first top-head actuator to exert a first resistive force on the top head and controlling the at least one second top-head actuator to exert a second resistive force on the top head, wherein the resistive force is equal to a sum of the first resistive force and the second resistive force.

31. The method of claim 30, further comprising determining that the switching condition has been met responsive to a case-position sensor detecting the case.

32. The method of claim 31, wherein the case-position sensor is configured to detect the case beneath the top head.

33. The method of claim 28, wherein: moving the top head to the height comprises controlling at least one first top-head actuator to move the top head to the height;maintaining the top head at the height comprises controlling the at least one first top-head actuator to maintain the top head at the height; stop maintaining the top head at the height comprises controlling the at least one first tophead actuator to stop maintaining the top head at the height; and exerting the resistive force on the top head comprises controlling at least one second tophead actuator to exert the resistive force on the top head.

34. The method of claim 33, further comprising: responsive to determining that the switching condition has been met, switching a clutch from an engaged state in which the clutch operably connects the at least one first top-head actuator to the top head to a disengaged state in which the clutch does not operably connect the at least one first top-head actuator to the top head.

35. The method of claim 32, wherein the switching condition is met responsive to a case-position sensor detecting the case.

36. The method of claim 35, wherein the case-position sensor is configured to detect the case beneath the top head.

37. The method of claim 28, wherein: moving the top head to the height comprises controlling at least one top-head actuator to move the top head to the height; maintaining the top head at the height comprises controlling the at least one top-head actuator to maintain the top head at the height; stop maintaining the top head at the height comprises controlling the at least one top-head actuator to stop maintaining the top head at the height; and exerting the resistive force on the top head comprises controlling the at least one top-head actuator to exert the resistive force on the top head.

38. The method of claim 37, further comprising determining that the switching condition has been met responsive to a case-position sensor detecting the case.

39. The method of claim 38, wherein the case-position sensor is configured to detect the case beneath the top head.

40. The method of claim 28, further comprising determining that the switching condition has been met responsive to a case-position sensor detecting the case.

41. The method of claim 40, wherein the case-position sensor is configured to detect the case beneath the top head.

42. The method of claim 28, further comprising determining the height based on the height of the case.

43. The method of claim 42, further comprising receiving data representing the height of the case.

44. The method of claim 42, further comprising sensing the height of the case.

45. The method of claim 28, further comprising receiving data representing the height.

46. The method of claim 28, wherein the switching condition comprises a first switching condition, the method further comprising: determining that a second switching condition has been met; and responsive to determining that the second switching condition has been met, controlling the top-head-actuating assembly to stop exerting the resistive force on the top head and resume maintaining the top head at the height.

47. The method of claim 46, wherein the first switching condition is met responsive to a first sensor detecting the case beneath the top head, wherein the second switching condition is met responsive to a second sensor detecting the case exiting from beneath the top head.

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