Systems, methods, and devices for applying a corner post

Abstract

Various embodiments of the present disclosure provide a corner post applicator system. The corner post applicator system includes a packaging machine, a track, and a corner post applicator. The packaging machine includes a packaging area for packaging a load. The corner post applicator includes a body engaged with the track, where the body is configured to move along the track from a first position to a second position. The corner post applicator also includes an arm coupled to the body, a horizontal positioner coupled to the arm, and a corner post gripper coupled to the horizontal positioner.

Description

SYSTEMS, METHODS, AND DEVICES FOR APPLYING A CORNER POSTPRIORITY

[0001] This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 642,389, filed May 3, 2024, the entire contents of which is incorporated herein by reference.FIELD

[0002] The present disclosure relates to applicators, and more particularly to a corner post applicator and method of use.BACKGROUND

[0003] Goods are often stacked on a pallet for ease of transportation from one location to another. The stack of goods on the pallet is typically unitized before transportation to secure the stack as a single unit, reducing a likelihood of some of the goods falling off the stack during transportation. A variety of securing mechanisms can be used to unitize the stack of goods including straps, cordage, and plastic stretch film.

[0004] In some instances, corner posts are applied to the corners of the stack. The corner posts provide edge protection and rigidity to the stack to further support and unitize the stack during transport. Corner post applicators can be used to apply the corner posts to the stack. Typically corner post applicators are fixedly positioned within a packaging machine to apply the corner posts to the stack while the stack is positioned within a packaging area of the packaging machine, though the size and shape of some packaging machines do not allow for the inclusion of fixed position corner post applicators within the packaging area. One downside of a corner post applicator within the packaging area is that the corner posts are not applied to the stack until the stack reaches the packaging area, which increases cycle time and decreases throughput.SUMMARY

[0005] Various embodiments of the present disclosure provide a corner post applicator system, a method for applying corner posts to a load, and a corner post applicator.

[0006] In one embodiment, a corner post applicator system includes a packaging machine, a track, and a corner post applicator. The packaging machine includes a packaging area for packaging a load. The corner post applicator includes a body engaged with the track, an arm coupled to the body, a horizontal positioner coupled to the arm, and a corner post gripper coupled to the horizontal positioner. The body is configured to move along the track from a first position to a second position.

[0007] In one embodiment, a method for applying corner posts to a load includes receiving a corner post at a corner post applicator. The corner post applicator includes a body and a corner post gripper coupled to the body, where the corner post is received by the corner post gripper. The method also includes determining, based on at least one dimension of the load, a placement location of the corner post on the load. The method also includes positioning, via the corner post gripper, the corner post against the load at the determined placement location. The method also includes moving the corner post applicator from a first position outside of a packaging machine to a second position inside of the packaging machine. The method also includes disengaging the corner post gripper from the corner post. The method also includes moving the corner post applicator from the second position to the first position.

[0008] In one embodiment, a corner post applicator includes a body, an arm coupled to the body, a horizontal positioner coupled to the arm, and a corner post gripper coupled to the horizontal positioner. The corner post gripper includes a gripper body and a gripper head coupled to the gripper body.BRIEF DESCRIPTION OF THE FIGURES

[0009] Figure l is a schematic top plan view of one example embodiment of a corner post applicator system of the present disclosure.

[0010] Figure 2 is another schematic top plan view of the corner post applicator system of Figure 1.

[0011] Figure 3 is a block diagram showing certain components of the corner post applicator system of Figure 1.

[0012] Figure 4 is a perspective view of an example load.

[0013] Figure 5 is a schematic top plan view of the corner post applicator system of Figure 1 having corner post magazines.

[0014] Figure 6 is a perspective view of the corner post applicator system of Figure 1 showing the corner post positioned on the load.

[0015] Figure 7 is another perspective view of the corner post applicator system of Figure 1 showing the corner post positioned on the load.

[0016] Figure 8 is a perspective view of a portion of the corner post applicator system of Figure 6.

[0017] Figure 9 is a perspective view of one example embodiment of a corner post gripper of the present disclosure.

[0018] Figure 10 is a perspective view of the corner post gripper of Figure 9 showing the corner post gripper gripping a corner post.

[0019] Figure 11 is a perspective view of another example embodiment of a corner post gripper showing the corner post gripper gripping a corner post.DETAILED DESCRIPTION

[0020] 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 connections 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 mounted, connected, etc., are not intended to be limited to direct mounting methods but should be interpreted broadly to include indirect and operably 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.

[0021] Various embodiments of the present disclosure provide a corner post applicator system, a method for applying corner posts to a load, and a corner post applicator. In various situations it is desirable for corner posts to be applied in conjunction with one or more otherpackaging materials, such as strap, stretch film, or paper wrap. Applying corner posts traditionally increases cycle time of packaging a load. Further, spatial constraints within some packaging machines do not accommodate fixed position devices to apply the corner posts within a packaging area of the packaging machine, which results in a separate upstream step and additional time required to apply the corner posts. Accordingly, embodiments of the corner post applicator system, the method for applying corner posts to a load, and the corner post applicator of the disclosure reduce the cycle time of packaging a load and thus increase packaging operation efficiency.

[0022] Figures 1 and 2 show one example embodiment of a corner post applicator system 10 of the present disclosure. The corner post applicator system 10 includes a packaging machine 20, a conveyor C, a first and second track Ti and T2, and one or more corner post applicators 100. For example, in the embodiment shown at least one of the comer post applicators 100 is engaged with the first track Ti and at least one of the corner post applicators 100 is engaged with the second track T2. While the corner post applicator system 10 shown in Figures 1 and 2 include two corner post applicators 100, in other embodiments the corner post applicator system 10 includes another number of corner post applicators 100, such as only one corner post applicator 100.

[0023] The corner post applicator 100 includes a body 110, an arm 120 coupled to the body 110, a horizontal positioner 130 coupled to the arm 120, and a corner post gripper 140 coupled to the horizontal positioner 130. The arm 120 includes a first arm portion 120A and a second arm portion 120B coupled to the first arm portion 120A. In Figure 1 the corner post applicator 100 is at a first position, external the packaging machine 20, and in Figure 2 the corner post applicator 100 is at a second position, within the packaging machine 20.

[0024] The packaging machine 20 includes a frame configured to support one or more other components included in the packaging machine 20. The frame of the packaging machine 20 defines a packaging area 22 within its interior and has an infeed area 20A at which a load L is conveyed via the conveyor C into the packaging area 22 for packaging and an outfeed area 20B at which the load L is conveyed via the conveyor C from the packaging area 22 after packaging. In some embodiments, the packaging machine 20 is a wrapping machine, such as a stretch wrapping machine or a stretch-hooding machine. In other embodiments the packaging machine 20 is any other suitable packaging machine, such as a strapping machine.

[0025] Figure 3 is a block diagram showing one or more components of the corner post applicator system 10. In certain embodiments, the corner post applicator system 10 includes a controller 600 for carrying out one or more operations of applying corner posts to a load. The controller 600 includes a processing device communicatively connected to a memory device. The processing device may include any suitable processing device such as, but not limited to, a general-purpose processor, a special-purpose processor, a digital-signal processor, one or more microprocessors, one or more microprocessors in association with a digital-signal processor core, one or more application-specific integrated circuits, one or more field- programmable gate array circuits, one or more integrated circuits, and / or a state machine. The controller 600 may have any suitable architecture such as single / multi-processor architectures and sequential / parallel architectures.

[0026] The memory device of the controller 600 may be a non-transitory computer readable medium. For example, the memory device may include any suitable memory device such as, but not limited to, read-only memory, random-access memory, one or more digital registers, cache memory, one or more semiconductor memory devices, magnetic media such as integrated hard disks and / or removable memory, magneto-optical media, and / or optical media. The memory device stores instructions executable by the processing device to control operation of the corner post applicator 100. The instructions provide logic and routines that enable the corner post applicator 100 to perform operations and / or functions.

[0027] In various such embodiments, the controller 600 is communicably coupled to the corner post applicator 100 and one or more corner post applicator actuators 30. In such embodiments, the controller 600 controls one or more components of the corner post applicator 100 via actuation of the corner post applicator actuators 30. In certain embodiments, the controller 600 controls one or more operations of the corner post applicator 100 based on at least one dimension of the load. For example, the controller 600 determines a desired placement location of the corner post on the load based one at least one dimension of the load. The controller 600 then controls the corner post applicator 100 to perform one or more corner post application operations based on the determination.

[0028] The controller 600 is further communicably coupled to an operator interface 500. The operator interface 500 is configured to receive inputs from an operator, and in certain embodiments, to output information to the operator. The operator interface 500 includes one or more input devices configured to receive the input from the operator. In variousembodiments, the one or more input devices include one or more buttons (such as hard or soft keys), one or more switches, and / or a touch panel. In various embodiments, the operator interface 500 includes a display device configured to display information to the operator, such as information about the load (e.g., contents and / or dimensions), information about the corner posts, and / or position information of the comer posts on the load. In certain embodiments, the operator interface 500 is remote from the corner post applicator 100.

[0029] In certain such embodiments, the controller 600 receives input from the operator via the operator interface 500 to adjustably control the one or more operations of the corner post applicator 100. For example, in certain embodiments the operator inputs one or more load dimensions into the operator interface 500 which the controller 600 uses to control movement of the corner post applicator 100 to correctly position the corner post on the load. In various embodiments, the controller 600 is communicatively coupled to the packaging machine 20 such that one or more operations of the packaging machine 20 and one or more operations of the corner post applicator 100 are controlled by the controller 600. In some embodiments, the packaging machine 20 includes a separate controller that has the same or similar form as the controller 600.

[0030] The first track Ti is disposed along a length of the conveyor C. For example, the first track Ti is disposed along a length of the conveyor C such that the first track Ti is substantially parallel with the conveyor C. A portion of the first track Ti is disposed within the packaging area 22 of the packaging machine 20. For example, the first track Ti is disposed along a portion of the conveyor C prior to entering the infeed area 20A and proceeds along the conveyor C through the infeed area 20A and within the packaging area 22 of the packing machine 20. Thus, in various embodiments the first track Ti includes a portion of the first track Ti that is external (e.g., outside of or not disposed within) the packaging machine 20 and internal (e.g., within) the packaging machine 20. In certain embodiments the second track T2 is arranged and / or configured the same or similar to the first track Ti. The terms substantially parallel, substantially planar, and substantially constant, as used herein, mean a variance within 20 degrees of parallel, planar, and constant, respectively.

[0031] In various embodiments, the first track Ti is configured to engage with the corner post applicator 100. For example, the body 110 of the corner post applicator 100 engages with the first track Ti. In such embodiments, the first track Ti defines a path that the cornerpost applicator 100 is movable along. The corner post applicator 100 is movable along the first track Ti from a first position to a second position, different than the first position.

[0032] In certain embodiments, the first position is external the packaging machine 20 and the second position is within the packaging machine 20, such as disposed within the packaging area 22. In such embodiments, the corner post applicator 100 is movable along the first track Ti from the first position external the packaging machine 20 to the second position disposed within the packaging area 22 of the packaging machine 20, and vice versa. In certain embodiments, the first track Ti includes a rail and / or beam; however any suitable configuration for the first track Ti may be used, such as a groove and / or channel. In further embodiments, the first track Ti is a conveyor configured to convey the corner post applicator 100 from the first position to the second position and / or from the second position to the first position.

[0033] Certain packaging machines include spatial constraints that make including a fixed position corner post applicator within the packaging area unfeasible. By enabling movement of the corner post applicator 100, the first track Ti allows the corner post applicator 100 to be disposed within the packaging area 22 during one or more packaging operations and disposed external the packaging machine 22 during one or more different packaging operations. Thus, in various embodiments the corner post applicator 100 allows for one or more corner post application operations to be performed within a packaging area without interfering with packaging operations by the packaging machine 20.

[0034] Further, in certain embodiments the corner post applicator system 10 decreases an amount of cycle time of packaging the load L. For example, the corner post applicator 100 begins applying one or more corner posts CP to the load L while the load L is external the packaging machine 20. In certain such embodiments, the corner post applicator 100 applies the one or more corner posts CP to the load while the conveyor C is conveying the load L towards and / or into the packaging machine 20. The corner post applicator 100 moves along the first track Ti with the load L while the load L is moved by the conveyor C through the infeed area 20A and into the packaging area 22 (as best shown in Figure 2). After one or more packaging operations are performed by the packaging machine 20, such as securing the one or more corner posts CP to the load L, the comer post applicator 100 moves along the first track Ti to a position external the packaging machine 20 to begin applying one or more corner posts CP to a second load. In such embodiments, the corner post applicator 100performs corner post application operations on a subsequent load while packaging operations are performed on the load L. Thus, the corner post applicator system 10 reduces cycle time by enabling the corner post applicator 100 to perform corner post application operations on a subsequent load during performance of one or more packaging operations on the load L by the packaging machine 20. Further, moving the corner post applicator 100 along the first track Ti reduces cycle time by allowing the corner post applicator 100 to apply the one or more corner posts CP to the load L while the load L is being conveyed into the packaging area 20.

[0035] In various embodiments, the corner post applicator system 10 includes a drive unit 150 coupled to the corner post applicator 100. The drive unit 150 (e.g., a motor) is configured to cause movement of the corner post applicator 100. For example, the drive unit 150 moves the corner post applicator 100 along the first track Ti from the first position to the second position and / or from the second position to the first position. In some embodiments, the drive unit 150 is controllable to be engaged and / or disengaged from the corner post applicator 100. For example, the drive unit 150 is disengaged from the corner post applicator 100 to allow the corner post applicator 100 to be synchronously moved from the first position to the second position by engagement with the load L traveling along the conveyor C, then reengaged with the corner post applicator 100 at the second position to cause movement of the corner post applicator 100 from the second position to the first position.

[0036] In various embodiments, the corner post applicator 100 is movable along the first track Ti using a rack-and-pinion configuration. For example, the first track Ti includes a rack and the corner post applicator 100 includes a pinion. In such embodiments, the drive unit 150 is coupled to the corner post applicator 100 and configured to actuate the pinion to cause movement of the corner post applicator 100 along the rack from the first position to the second position and / or from the second position to the first position. While in some embodiments, the drive unit 150 is a rotary motor that engages the pinion to effect movement of the corner post applicator 100, in other embodiments a different drive unit is used to cause movement of the pinion relative to the rack.

[0037] In certain embodiments, the drive unit 150 is coupled to the corner post applicator 100 through one or more mechanical linkages, such as a chain or belt, where movement of the corner post applicator 100 along the first track Ti occurs through actuation of the one or more mechanical linkages. For example, the mechanical linkage may be disposed near, orcoupled to, the first track Ti such that actuation of the mechanical linkage by the drive unit 150 produces movement of the corner post applicator 100 along the first track Ti. While in some embodiments the drive unit 150 is mounted on the corner post applicator 100, in other embodiments the drive unit 150 is remote from the corner post applicator 100. In various embodiments, the drive unit 150 is controllable by the controller 600.

[0038] In certain embodiments, the drive unit 150 is further engaged with the corner post applicator 100 to cause actuation of the one or more components of the corner post actuator 100. For example, the drive unit 150 causes actuation of the arm 120A and 120B, the horizontal positioner 130, and / or the corner post gripper 140. Thus, in some embodiments the drive unit 150 is configured to provide movement of the corner post applicator 100 while also causing actuation of the one or more components of the corner post actuator 100.

[0039] The arm 120 is coupled at a first end to the body 110 and at a second end to the horizontal positioner 130, such as coupled to the body 110 at the first arm portion 120 A and coupled to the horizontal positioner 130 at the second arm portion 120B. In certain embodiments, the arm 120 is movable in a Y axis direction (as best shown Figure 1) between a retracted position and an extended position. For example, the second arm portion 120B extends in the Y axis direction from the first arm portion 120A. Figures 6 and 7 show the corner post applicator 100 positioning the corner post CP on the load L. Extension of the second arm portion 120B allows the corner post applicator 100 to position the horizontal positional 130 near the load L. A distance that the second arm portion 120B extends is based on a position of the load L on the conveyor C. Thus, in such embodiments the Y axis position of the horizontal positioner 130 is based on a position of the arm 120.

[0040] The horizontal positioner 130 functions to horizontally position the corner post CP on the load L, such as to horizontally align the comer post CP via the corner post gripper 140 at a corner of the load L. The horizontal positioner 130 includes a beam, or other suitable structure, to allow coupling with the corner post gripper 140. In various embodiments, a length of the horizontal positioner 130 is greater than or equal to a dimension of the load L, such as a length and / or width. Having a length greater than or equal to the dimension of the load L allows for multiple corner posts to be applied to the load during a single operation as well as accommodating loads of varying sizes. For example, in such embodiments the horizontal positioner 130 includes a first and a second corner post gripper, where the firstcorner post gripper applies a first corner post CP to a first corner of the load L and the second corner post gripper applies a second corner post CP to a second corner of the load L.

[0041] While the corner post gripper 140 is coupled to the horizontal positioner 130, this is merely one example configuration, and in various other embodiments the corner post gripper 140 is coupled to another component of the corner post applicator 100. For example, in some embodiments the corner post gripper 140 is coupled to the arm 120. In such embodiments, the horizontal positioner 130 is coupled to the body 110 and the arm 120 to position the corner post gripper 140, via the arm 120, at a determined position.

[0042] In various embodiments, the corner post gripper 140 is movably coupled to the horizontal positioner 130 such that the corner post gripper 140 is free to translate along a portion of the length of the horizontal positioner 130 in the X axis direction (Figures 1 and 8). Translation of the corner post gripper 140 along the horizontal positioner 130 allows the corner post gripper 140 to adjust a horizontal location of the corner post CP to correctly match with a dimension of the load L. In various embodiments, the corner post gripper 140 is rotatable relative to the horizontal positioner 130 such that an angle (e.g., between 0 and 180 degrees) made between the horizontal positioner 130 and the corner post gripper 140 is nonconstant. Rotation of the corner post gripper 140 relative to the horizontal positioner 130 allows the corner post gripper 140 to adjust an orientation of the corner post CP to align with an orientation of the corner of the load L.

[0043] In certain embodiments, a first load includes a first length and a second load includes a second length different than the first length. In such embodiments, the horizontal placement of the corner post CP on the first load is different than the horizontal placement of the corner post CP on the second load. The corner post gripper 140 moves along the horizontal positioner 130 to adjust a horizontal position of the corner post CP which allows the corner post gripper 140 to correctly match a position of the corner post CP with a corner of the load L. Thus, by moving along the horizontal positioner 130 the corner post gripper 140 is able to accommodate loads having varying dimensions while still placing the corner post CP at a determined horizontal location (e.g., the corner of the load L).

[0044] In certain embodiments, the horizontal positioner 130 includes one or more components to facilitate movement of the one or more corner post grippers 140. For example, in some embodiments the horizontal positioner 130 is engaged with the one or more corner post grippers 140 via a mechanical linkage (e.g., a chain, belt, or track) configured to movethe one or more corner post grippers 140 along a length of the horizontal positioner 130. In other embodiments, another actuation mechanism is used, such as a pneumatic and / or hydraulic coupling between the corner post gripper 140 and the horizontal positioner 130.

[0045] In various embodiments, the corner post applicator 100 includes a vertical positioner configured to adjust a vertical position of the corner post gripper 140. In some embodiments, the arm 120 includes the vertical positioner, such that a vertical position of the arm 120 is adjustable by the vertical positioner. However, in other embodiments the horizontal positioner 130 includes the vertical positioner to allow adjusting a vertical position of the horizontal positioner 130. Thus, in such embodiments the horizontal positioner 130 further adjusts a vertical position of the corner post gripper 140. When the corner post gripper 140 is positioning the corner post CP on the load L the vertical positioner adjusts a vertical position of the corner post gripper 140 such that the corner post CP is applied to the load L at a desired height. For example, loads often vary in height, with some loads being disposed on a pallet while other loads are not disposed on the pallet. In such examples, the vertical positioner enables the corner post gripper 140 to adjust between a first vertical position and a second vertical position which allows the corner post CP to be placed at the desired height on the load L.

[0046] While in some embodiments the vertical positioner is a separate component, in other embodiments one or more components of the corner post applicator 100 have multiple axis of freedom. For example, in certain embodiments the arm 120 is movable in both the Y axis as well as in a vertical plane orthogonal to the Y axis. In such embodiments, the arm 120 is configured to provide multiaxial movement of the horizontal positioner 130 such that the horizontal positioner 130 is near the load in the Y axis direction and vertically disposed at the desired corner post application position.

[0047] As shown in Figures 9 and 10, the corner post gripper 140 includes a gripper body 142 and a first and second gripper head portions 144A and 144B coupled to the gripper body 142. The gripper body 142 includes a frame that defines a first end 142A, a second end 142B opposite the first end, and a horizontal length defined between the first and second ends 142 A and 142B. In various embodiments, the gripper body 142 defines a channel 142C disposed along a portion of the horizontal length, such as a channel disposed between the first and second ends 142 A and 142B.

[0048] In various embodiments, the first and second gripper head portions 144 A and 144B are configured to mate with the channel 142C. For example, a portion of the first and second gripper head portions 144A and 144B is disposed within the channel 142C to provide coupling between the first and second gripper head portions 144 A and 144B and the gripper body 142. In such embodiments, the first and second gripper head portions 144A and 144B are movably coupled to the gripper body 142 such that the first and second gripper head portions 144 A and 144B are translatable, via the channel 142C, along a portion of the length of the gripper body 142.

[0049] Each of the first and second gripper head portions 144A and 144B is movable along the channel 142C between an open position and a closed position. By translating along the length of the gripper body 142 between the open position and the closed position, an angle formed between the first and second gripper head portions 144A and 144B is substantially constant in the open and closed positions. Thus, in certain embodiments the first and second gripper head portions 144A and 144B open and close via substantially planar lateral movement along a portion of the length of the channel 142C such that an angle formed between the first and second gripper head portions 144A and 144B in the open position is the same as or substantially similar to an angle formed in the closed position.

[0050] The first and second gripper head portions 144 A and 144B each respectively include one or more support arms 146 coupled to a spacer 145. In various embodiments, the support arm 146 is coupled to the spacer 145 at an angle, such as a ninety degree angle. In embodiments where multiple support arms 146 are employed, each support arm 146 is separated from another support arm 146 by a distance defined by the spacer 145, such as being disposed on opposite ends of the spacer 145. In such embodiments, on each gripper head portion 144A and 144B, each support arm 146 is normal to another support arm 146 and orthogonal to the spacer 145. Separating the support arms 146 on each gripper head portion 144A and 144B by a distance defined by the spacer 145 allows corner post gripper 140 to more securely retain the corner post CP within the corner post gripper 140. For example, multiple points of contact between the corner post gripper 140 and the corner post CP allow for increased stability and control during handling which decreases a likelihood of the corner post CP becoming loose from the corner post gripper 140 when positioning on the load L.

[0051] In certain embodiments, the support arm 146 includes a tooth 148. The tooth 148 is oriented such that the tooth 148 is substantially parallel with the length of the body 142. Onthe first gripper head portion 144A the tooth 148 is oriented towards the second gripper head portion 144B, and on the second gripper head portion 144B the tooth 148 is oriented towards the first gripper head portion 144 A. Thus, in certain embodiments the first and second gripper head portions 144A and 144B are symmetric about an axis such that they mirror one another.

[0052] Figure 10 illustrates the corner post gripper 140 of Figure 9 in the closed position having the corner post CP gripped by the first and second gripper head portions 144 A and 144B. As illustrated in Figure 10, the corner post CP is retained within the teeth 148 of the first and second gripper head portions 144A and 144B. Thus, when the first and second gripper head portions 144 A and 144B are in the closed position the tooth 148 aids in restricting undesired movement of the corner post CP during one or more corner post application operations. Further, one or more portions of the support arm 146 are oriented such that they align with one or more dimensions of the corner post CP. For example, portions of the support arm 146 in contact with the corner post CP mirror the geometry of the corner post CP (e.g., an angle made by one or more sides of the corner post CP) such that the corner post CP is firmly secured within the first and second gripper head portions 144A and 144B.

[0053] To disengage the first and second gripper head portions 144A and 144B from the corner post CP, the first and second gripper head portions 144 A and 144B translate laterally along the channel 142C away from one another such that they are in the open position (as best shown in Figure 9). In the open position, the tooth 148 and the support arm 146 are no longer in direct contact with the corner post CP which allows the corner post gripper 140 to be moved away from the corner post CP without adversely affecting placement of the corner post CP on the load L. For example, in certain embodiments the position of the corner post CP on the load L is fixed after one or more packaging operations have been performed, such as partial wrapping and / or hooding of the load L which secures the position of the corner post CP on the load. In such embodiments, the corner post gripper 140 is actuated such that the first and second gripper head portions 144A and 144B are moved from the closed position to the open position to release the grip of the corner post gripper 140 from the corner post CP. The corner post gripper 140 is then moved away from the load L to allow one or more additional packaging operations to be performed by the packaging machine 20.

[0054] In certain embodiments, the corner post applicator 100 includes another corner post gripper. Figure 11 illustrates a corner post gripper 240. The corner post gripper 240 includes a gripper body 240, a back plate 245, and first and second gripper head portions 244A and244B each including a tooth 248. In such embodiments the gripper body 242 and the tooth 248 are similar to the gripper body 142 and the tooth 148. The back plate 245 aids in positioning the corner post CP between the first and second gripper head portions 244A and 244B. For example, upon receiving the corner post CP from a magazine (Figure 5) the back plate 245 supports and / or guides the corner post CP to be positioned between the first and second gripper head portions 244A and 244B for gripping. In certain embodiments, the corner post gripper 240 includes a bottom ledge disposed at a distance below the first and second gripper head portions 244 A and 244B. In such embodiments, upon receiving the corner post CP from the magazine an end of the corner post CP settles on the bottom ledge.

[0055] In various embodiments, each of the first and second gripper head portions 244A and 244B are rotatably coupled to the gripper body 242 at a pivot point 246. The first and second gripper head portions 244A and 244B each respectively rotate about the pivot point 246 between an open position and a closed position. In the closed position the corner post CP is secured between the first and second gripper head portions 244A and 244B to allow the corner post applicator 100 to position the corner post CP on the load L. In such embodiments, an angle formed between the first and second gripper head portions 244A and 244B in the open position is different than an angle formed between the first and second gripper head portions 244A and 244B in closed position. To disengage the corner post gripper 240 from the corner post CP the first and second gripper head portions 244A and 244B are rotated from the closed position to the open position such that clamp up force is terminated between the corner post gripper 240 and the corner post CP. In certain such embodiments, as the first and second gripper head portions 244A and 244B are pressed into contact with the load L, the force biases open the first and second gripper head portions 244A and 244B to allow the corner post CP to be released and placed against the load. In such embodiments, the corner post gripper 240 is driven towards the load L until the back plate 245 secures the corner post CP against the load L. The corner post gripper 240 is then actuated away from the load L having the corner post CP to allow one or more packaging operations to be performed. In some embodiments, corner post gripper 240 is actuated away from the load L after performing at least one packaging operation, such as partially securing the corner post CP to the load L.

[0056] While the corner post gripper 240 uses clamp up force (e.g., through one or more springs) in the closed position to retain the corner post CP, in various other embodiments a suction force is used. For example, in certain embodiments a corner post gripper includes asuction device, such as one or more suction heads, that exert a suction force on the corner post CP to detachably (e.g., temporarily) secure the corner post gripper to the corner post CP. In certain embodiments, the suction device includes a suction generator in fluid communication with the one or more suction heads. The one or more suction heads are configured to engage with the corner post CP such that suction provided by the suction generator secures the one or more suction heads to the corner post CP. Suction force is maintained between the one or more suction heads and the corner post CP during corner post application operations, such as during placement and / or positioning of the corner post CP to the load L. In such embodiments, after the corner post CP is secured to the load L during one or more packaging operations the suction force to the one or more suction heads is terminated and the corner post gripper is disengaged from the corner post CP.

[0057] A position of the load L on the conveyor C is not always constant. Loads may be off of center on the conveyor C as well as oriented at an undesirable angle for corner post application. In certain embodiments, the comer post applicator system 10 includes a load positioner. The load positioner functions to adjust the position of the load L on the conveyor C. For example, the load positioner aligns the load L at a center location on the conveyor C and / or reorients the load L such that the one or more sides S of the load L are facing the corner post applicator 100. In some embodiments the load positioner is coupled to one or more components of the corner post applicator 100, such as the horizontal positioner 130. However, in other embodiments the load positioner is separate from the corner post applicator 100, for example being part of the corner post applicator system 10 in an upstream step from the corner post applicator 100.

[0058] Figure 5 illustrates the corner post applicator system 10 of Figure 1 having corner post magazines. In various embodiments, the corner post applicator system includes one or more magazines (e.g. a corner post magazine), such as a first magazine Ml and a second magazine M2. Each of the first and second magazines Ml and M2 are configured to retain and / or dispense one or more corner posts. For example, in certain embodiments the first magazine Ml retains and / or dispenses a corner post having a first dimension and the second magazine M2 retains and / or dispenses a corner post having a second dimension different than the first dimension. Thus, in various embodiments the first and second magazines Ml and M2 are operable to retain and / or dispense one or more different sizes of corner posts. While Figure 5 illustrates a first and second magazine Ml and M2, in other embodiments one or more different magazines may be used.

[0059] Figure 4 illustrates an example load L that undergoes one or more packaging operations. The load L includes a top T, a bottom B opposite the top T, and a plurality of sides S disposed between the top T and the bottom B. While the load L shown in Figure 4 is disposed on a pallet P, in other embodiments the load L does not include the pallet P. The load L is defined by one or more dimensions, such as a width, a height, and / or a length. Loads undergoing packaging by the packaging machine 20 often have geometric variations between each other. For example, a height, width, and / or length of a first load may be different from a height, width, and / or length of a second load.

[0060] In such examples, it is desirable to select a corner post CP that pairs with the dimensions of the load to be packaged such that the corner post CP effectively secures the load L when packaged. Including one or more magazines in the corner post applicator system 10, where each magazine retains and / or dispenses a corner post having at least one dimension different from a corner post in another magazine enables a corner post to be selected that compliments a dimension on the load L. Thus, in certain embodiments the corner post CP is received by the corner post applicator 100 from the one or more magazines, where the corner post CP received is based on one or more dimensions of the load L.

[0061] As illustrated in Figure 5, the first and second magazines Ml and M2 are disposed near a position of the corner post applicator 100, such as at the first position of the corner post applicator 100 external the packaging machine 20. The first and second magazines Ml and M2 are positioned near the corner post applicator 100 such that the corner post applicator 100 is able to interact with the first and second magazines Ml and M2. For example, the corner post applicator 100 interacts with either the first and / or second magazine Ml and M2 to receive a corner post CP from the respective magazine for application on the load L.

[0062] In various embodiments, the one or more dimensions from the load L are used to determine a particular corner post CP to be applied to the load L. For example, where each magazine (e.g., Ml and M2) contains corner posts having varying dimensions a particular corner post is determined from the plurality of comer posts based on the one or more dimensions of the load L. The corner post applicator 100 then receives the particular corner post from the respective magazine for application on the load L. For example, the corner post applicator 100 receives the particular corner post from the respective magazine at the corner post gripper 140.

[0063] In certain embodiments where multiple magazines are present, the corner post applicator 100 is movable along the first and / or second track Ti and / or T2 to align the corner post gripper 140 with the respective magazine. In other embodiments, one or more components of the corner post applicator 100 are movable to engage the respective magazine to receive the corner post CP. For example, in some embodiments the corner post gripper 140 moves along the horizontal positioner 130, and / or is movable via the arm 120, to engage the respective magazine. In further embodiments, the one or more magazines (e.g., Ml and M2) are movable, such as on a rotating carousel, such that the desired corner post is received by the corner post gripper 140.

[0064] Thus, in various embodiments, the present disclosure provides a corner post applicator system. The corner post applicator system comprises a packaging machine, a track, and a corner post applicator. The packaging machine includes a packaging area for packaging a load. The corner post applicator comprises a body engaged with the track, where the body is configured to move along the track from a first position to a second position. The corner post applicator also comprises an arm coupled to the body, a horizontal positioner coupled to the arm, and a corner post gripper coupled to the horizontal positioner.

[0065] In various such embodiments of the corner post applicator system, the corner post gripper is rotatable between a first position and a second position.

[0066] In various such embodiments of the corner post applicator system, the corner post gripper is translatable along a length of the horizontal positioner between a first position and a second position.

[0067] In various such embodiments of the corner post applicator system, the corner post gripper comprises a gripper body and a gripper head coupled to the gripper body. The gripper head comprises a first gripper head portion coupled to the gripper body and a second gripper head portion coupled to the gripper body. Each of the first and second gripper head portions is movable between an open position and a closed position, by translating along a length of the gripper body, such that an angle formed between the first and second gripper heads is substantially constant in the open and closed position.

[0068] In various such embodiments of the corner post applicator system, the corner post gripper comprises a gripper body and a gripper head coupled to the gripper body. The gripper head comprises a first gripper head portion coupled to the gripper body and a second gripper head portion coupled to the gripper body. Each of the first and second gripper head portionsis rotatable between an open position and a closed position such that an angle formed by the first and second gripper heads is different between the open and closed position.

[0069] In various such embodiments of the corner post applicator system, the arm is movable in a first direction between a retracted position and an extended position.

[0070] In various such embodiments, the corner post applicator system further comprises a second arm coupled to the body, where the second arm is movable in a vertical direction between a first vertical position and a second vertical position different than the first vertical position.

[0071] In various such embodiments of the corner post applicator system, a length of the horizontal positioner is adjustable between a first horizontal length and a second horizontal length, and the second horizontal length is based at least in part on a dimension of a load.

[0072] In various such embodiments, the corner post applicator system further comprises a first corner post magazine, wherein the first corner post magazine is configured to engage with the corner post gripper to dispense a first corner post into the corner post gripper.

[0073] In various such embodiments, the corner post applicator system further comprises a second corner post magazine, wherein the second corner post magazine is configured to engage with the corner post gripper to dispense a second corner post into the corner post gripper, and wherein the first corner post has at least one dimension different than the second corner post.

[0074] In various such embodiments of the corner post applicator system, the body is external the packaging machine at the first position and disposed within the packaging machine at the second position.

[0075] In various such embodiments, the corner post applicator system further comprises a conveyor configured to move the load within the packaging area of the packaging machine, wherein the track is disposed along a length of the conveyor.

[0076] In various other embodiments, the disclosure provides a method for applying a corner post to a load. The method includes receiving a corner post at a corner post applicator, the corner post applicator comprising a body and a corner post gripper coupled to the body, where the corner post is received by the corner post gripper. The method also includes determining, based on at least one dimension of the load, a placement location of the cornerpost on the load. The method also includes positioning, via the corner post gripper, the corner post against the load at the determined placement location. The method also includes moving the corner post applicator from a first position outside of a packaging machine to a second position inside of the packaging machine. The method also includes disengaging the corner post gripper from the corner post. The method also includes moving the corner post applicator from the second position to the first position.

[0077] In various such embodiments of the method, before receiving the corner post at the corner post applicator the method further comprises determining, based on the at least one dimension of the load, a particular corner post from a plurality of corner post magazines, wherein each corner post magazine contains corner posts having varying dimensions.

[0078] In various such embodiments of the method, determining the placement location of the corner post on the load further comprises determining a horizontal placement of the corner post; and determining a vertical placement of a first end of the corner post.

[0079] In various such embodiments of the method, where the load is conveyed by a conveyor, the method further comprises determining a placement location of the load on the conveyor; and positioning the load on the conveyor at the determined placement location.

[0080] In various such embodiments of the method, the corner post applicator is coupled to a drive unit.

[0081] In various such embodiments of the method, the drive unit moves the corner post applicator from the first position to the second position synchronously with the load.

[0082] In various such embodiments of the method, moving the corner post applicator from the first position to the second position further comprises disengaging the corner post applicator from the drive unit, such that the corner post applicator is moved synchronously with the load via movement of the conveyor.

[0083] In various such embodiments of the method, moving the corner post applicator from the second position to the first position further comprises re-engaging the corner post applicator with the drive unit; and actuating the drive unit to drive the corner post applicator from the second position to the first position.

[0084] In various such embodiments of the method, the corner post gripper is disengaged from the corner post after the corner post is at least partially packaged by the packaging machine.

[0085] In various such embodiments of the method, the corner post is engaged by the corner post applicator using clamp up force and disengaging the corner post gripper from the corner post comprises removing the clamp up force between the corner post and the corner post applicator.

[0086] In various such embodiments of the method, the corner post applicator further comprises an arm coupled to the body and a horizontal positioner coupled to the arm, and wherein the corner post gripper is coupled to the horizontal positioner.

[0087] In various such embodiments of the method, the corner post gripper is translatable along a length of the horizontal positioner between a first position and a second position.

[0088] In various such embodiments of the method, the corner post gripper is rotatable between a first position and a second position.

[0089] In various such embodiments of the method, the corner post gripper comprises a gripper body; a first gripper head portion coupled to the gripper body; and a second gripper head portion coupled to the gripper body. Each of the first and second gripper head portions is movable between an open position and a closed position, by translating along a length of the gripper body, such that an angle formed between the first and second gripper heads is substantially constant in the open and closed position.

[0090] In various such embodiments of the method, the corner post gripper comprises a gripper body; a first gripper head portion coupled to the gripper body; and a second gripper head portion coupled to the gripper body. Each of the first and second gripper head portions is rotatable between an open position and a closed position such that an angle formed between the first and second gripper head portions is different between the open and closed position.

[0091] In various other embodiments, the disclosure provides a corner post applicator. The corner post applicator comprises a body; an arm coupled to the body; a horizontal positioner coupled to the arm; and a corner post gripper coupled to the horizontal positioner. The corner post gripper comprises a gripper body and a gripper head coupled to the gripper body.

[0092] Various changes and modifications to the above-described embodiments described herein will be apparent to those skilled in the art. These changes and modifications can be made without departing from the spirit and scope of this present subject matter and without diminishing its intended advantages. Not all of the depicted components described in this disclosure may be required, and some implementations may include additional, different, or fewer components from those expressly described in this disclosure. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of attachment and connections of the components may be made without departing from the spirit or scope of the claims as set forth herein. Also, unless otherwise indicated, any directions referred to herein reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the invention as taught herein and understood by one of ordinary skill in the art.

Claims

CLAIMS1. A corner post applicator system comprising: a packaging machine comprising a packaging area for packaging a load; a track; and a corner post applicator comprising: a body engaged with the track, the body configured to move along the track from a first position to a second position; an arm coupled to the body; a horizontal positioner coupled to the arm; and a corner post gripper coupled to the horizontal positioner.

2. The corner post applicator system of claim 1, wherein the corner post gripper is rotatable between a first position and a second position.

3. The corner post applicator system of claim 1, wherein the corner post gripper is translatable along a length of the horizontal positioner between a first position and a second position.

4. The corner post applicator system of claim 1, wherein the corner post gripper comprises a gripper body and a gripper head coupled to the gripper body, the gripper head comprising: a first gripper head portion coupled to the gripper body; and a second gripper head portion coupled to the gripper body, wherein each of the first and second gripper head portions is movable between an open position and a closed position, by translating along a length of the gripper body, such that an angle formed between the first and second gripper heads is substantially constant in the open and closed position.

5. The corner post applicator system of claim 1, wherein the corner post gripper comprises a gripper body and a gripper head coupled to the gripper body, the gripper head comprising: a first gripper head portion coupled to the gripper body; and a second gripper head portion coupled to the gripper body,wherein each of the first and second gripper head portions is rotatable between an open position and a closed position such that an angle formed by the first and second gripper heads is different between the open and closed position.

6. The corner post applicator system of claim 1, wherein the arm is movable in a first direction between a retracted position and an extended position.

7. The corner post applicator system of claim 6, further comprising a second arm coupled to the body, wherein the second arm is movable in a vertical direction between a first vertical position and a second vertical position different than the first vertical position.

8. The corner post applicator system of claim 6, wherein a length of the horizontal positioner is adjustable between a first horizontal length and a second horizontal length, and wherein the second horizontal length is based at least in part on a dimension of a load.

9. The corner post applicator system of claim 1, further comprising a first corner post magazine, wherein the first corner post magazine is configured to engage with the corner post gripper to dispense a first corner post into the corner post gripper.

10. The corner post applicator system of claim 9, further comprising a second corner post magazine, wherein the second corner post magazine is configured to engage with the corner post gripper to dispense a second corner post into the corner post gripper, and wherein the first corner post has at least one dimension different than the second corner post.

11. The corner post applicator system of claim 1, wherein the body is external the packaging machine at the first position and disposed within the packaging machine at the second position.

12. The corner post applicator system of claim 1, further comprising a conveyor configured to move the load within the packaging area of the packaging machine, wherein the track is disposed along a length of the conveyor.

13. A method for applying a corner post to a load, the method comprising: receiving a corner post at a corner post applicator, the corner post applicator comprising a body and a corner post gripper coupled to the body, wherein the corner post is received by the corner post gripper; determining, based on at least one dimension of the load, a placement location of the corner post on the load; positioning, via the corner post gripper, the corner post against the load at the determined placement location; moving the corner post applicator from a first position outside of a packaging machine to a second position inside of the packaging machine; disengaging the corner post gripper from the corner post; and moving the corner post applicator from the second position to the first position.

14. The method of claim 13, wherein the method further comprises: before receiving the corner post at the corner post applicator, determining, based on the at least one dimension of the load, a particular corner post from a plurality of corner post magazines, wherein each corner post magazine contains corner posts having varying dimensions.

15. The method of claim 13, wherein determining the placement location of the corner post on the load further comprises: determining a horizontal placement of the corner post; and determining a vertical placement of a first end of the corner post.

16. The method of claim 13, wherein the load is conveyed by a conveyor, the method further comprising: determining a placement location of the load on the conveyor; and positioning the load on the conveyor at the determined placement location.

17. The method of claim 13, wherein the corner post applicator is coupled to a drive unit.

18. The method of claim 17, wherein the drive unit moves the corner post applicator from the first position to the second position synchronously with the load.

19. The method of claim 17, wherein moving the corner post applicator from the first position to the second position further comprises: disengaging the corner post applicator from the drive unit, such that the corner post applicator is moved synchronously with the load via movement of the conveyor.

20. The method of claim 17, wherein moving the corner post applicator from the second position to the first position further comprises: re-engaging the corner post applicator with the drive unit; and actuating the drive unit to drive the corner post applicator from the second position to the first position.

21. The method of claim 13, wherein the corner post gripper is disengaged from the corner post after the corner post is at least partially packaged by the packaging machine.

22. The method of claim 13, wherein the corner post is engaged by the corner post applicator using clamp up force and disengaging the corner post gripper from the corner post comprises removing the clamp up force between the corner post and the corner post applicator.

23. The method of claim 13, wherein the corner post applicator further comprises an arm coupled to the body and a horizontal positioner coupled to the arm, and wherein the corner post gripper is coupled to the horizontal positioner.

24. The method of claim 23, wherein the corner post gripper is translatable along a length of the horizontal positioner between a first position and a second position.

25. The method of claim 13, wherein the corner post gripper is rotatable between a first position and a second position.

26. The method of claim 13, wherein the corner post gripper comprises: a gripper body; a first gripper head portion coupled to the gripper body; and a second gripper head portion coupled to the gripper body,wherein each of the first and second gripper head portions is movable between an open position and a closed position, by translating along a length of the gripper body, such that an angle formed between the first and second gripper heads is substantially constant in the open and closed position.

27. The method of claim 13, wherein the corner post gripper comprises: a gripper body; a first gripper head portion coupled to the gripper body; and a second gripper head portion coupled to the gripper body, wherein each of the first and second gripper head portions is rotatable between an open position and a closed position such that an angle formed between the first and second gripper head portions is different between the open and closed position.

28. A corner post applicator comprising: a body; an arm coupled to the body; a horizontal positioner coupled to the arm; and a corner post gripper coupled to the horizontal positioner, wherein the corner post gripper comprises a gripper body and a gripper head coupled to the gripper body.

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