Packaging machine with a corner protector applicator

Abstract

Various embodiments of the present disclosure provide systems and method for applying corner protectors to the corners of a load and holding them in place with a loop of packaging material.

Description

PACKAGING MACHINE WITH A CORNER PROTECTOR APPLICATORPriority

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 698,675, filed September 25, 2024, the entire contents of which is incorporated herein by reference.Field

[0002] The present disclosure relates to packaging machines for applying packaging material to loads, and more particularly to packaging machines that apply corner protectors to loads during the packaging process.Background

[0003] There are many types of packaging machines for applying packaging material to loads to unitize the loads in preparation for future transport. Some examples of these packaging machines include strapping machines that apply plastic, paper, or steel strap around loads and wrapping machines that apply plastic stretch film or paper around loads. Corner protectors are rigid, elongated, L-shaped members typically formed from plies of paperboard laminated to one another via adhesive. Corner protectors are typically positioned on the vertically oriented outer four corners of a load before the packaging material is applied and then held in place with the packaging material. After the packaging material is applied around the corner protectors and the load, the corner protectors act as barriers that protect the comers of the load from damage during transit and that stabilize the load.Summary

[0004] Various embodiments of the present disclosure provide systems and method for applying corner protectors to the corners of a load and holding them in place with a loop of packaging material.Brief Description of the Figures

[0005] Figure l is a diagrammatic top plan view of a wrapping system of the present disclosure.

[0006] Figure 2 is a block diagram showing certain components of the wrapping system of Figure 1.

[0007] Figures 3-16 are diagrammatic top plan views of the wrapping system of Figure 1 applying corners protectors to the four vertical corners of a load and forming a loop of packaging material around the comer protectors and the load.Detailed Description

[0008] 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.

[0009] Various embodiments of the present disclosure provide systems and method for applying corner protectors to the corners of a load and holding them in place with a loop of packaging material. Figures 1-16 show one embodiment of the wrapping system 10 of the present disclosure and the assemblies and components of the wrapping system 10. The wrapping system 10 includes a conveyor system, a wrapping device 100, a first corner-protector applicator 2000a, and a second corner-protector applicator 2000b. In this example embodiment, thewrapping system 10 is configured to form a loop of paper wrapping material WM (the packaging material in this example embodiment) from a roll R around a load.

[0010] The conveyor system supports a load and moves the load in a movement direction MD (Figure 1) relative to and between certain components of the wrapping device 100 and the first and second comer-protector applicators 2000a and 2000b. The conveyor system includes a conveyor 55 and one or more conveyor actuators 55a operably connected to the conveyor 55 and configured to drive the conveyor 55. Specifically, the conveyor 55 includes a conveyor frame 55f and multiple aligned rollers 55r rotatably supported by the conveyor frame 55f. The rollers 55r are not shown in Figures 3-16 for clarity. The one or more conveyor actuators 55a, which include one or more electric motors in this example embodiment but may include any suitable type of actuator(s), are operably connected to the conveyor rollers 55r through a suitable drive train — such as via gearing, chains, belts, and the like — and is configured to drive the conveyor rollers 55r. The conveyor may include one or more driven belts or any other suitable type of driven component instead of or in addition to drive rollers.

[0011] The wrapping device 100 forms a loop of the wrapping material WM around a load as the conveyor system moves the load relative to and through the wrapping device 100. The wrapping device 100 includes a roll-support assembly 200, a first roller assembly 300, a second roller assembly 400, a gripper assembly, an adhesive-applicator assembly, a cutter assembly, a controller 900, and one or more sensors S.

[0012] The roll-support assembly 200 supports and drives the roll R of wrapping material WM during the wrapping process. The roll-support assembly 200 includes a roll support 210 and a roll actuator 210a. The roll support 210 includes a platform 21 Op and a spindle 210s extending from and rotatable relative to the platform 21 Op. The platform 21 Op is sized, shaped, oriented, positioned, and otherwise configured to support the roll R. The spindle 210s is sized, shaped, oriented, positioned, and otherwise configured such that the central core of the roll R of the wrapping material WM can be slid onto the spindle 210s and fixed in rotation with the spindle 210s such that the roll R can rotate with the spindle 210s relative to the platform 210p. In certain embodiments, the spindle 210s includes radially outwardly biased friction members configured to fix the roll R in rotation with the spindle 210s via friction fit, though any other suitable manner may be employed. The roll actuator 210a, which includes an electric motor in this example embodiment but may be any other suitable actuator, is operably connected to thespindle 210s and configured to rotate the spindle 210s — and the roll R mounted to the spindle 210s — relative to the platform 210p. The roll-support assembly 200 is positioned next to the conveyor system.

[0013] The first roller assembly 300 manipulates the wrapping material WM during the wrapping process and, after the wrapping process is complete, feeds wrapping material WM to the second roller assembly 400 in preparation for the next wrapping process. The first roller assembly 300 includes a cylindrical first drive roller 310, a first-drive-roller actuator 310a, a cylindrical first idle roller 320, a first-roller-assembly actuator 300a, and a first-roller-assembly support (not shown for clarity). The first drive roller 310 and the first idle roller 320 are vertically oriented (into and out of the page from the perspective shown in Figures 1 and 3-16) and rotatably mounted to the first-roller-assembly support. A first biasing member (not shown), such as one or more springs, biases the first idle roller 320 into contact with the first drive roller 310. The first-drive-roller actuator 310a, which includes an electric motor in this example embodiment but may be any other suitable actuator, is operably connected to the first drive roller 310 and configured to rotate the first drive roller 310 relative to the first idle roller 320. The first idle roller 320, on the other hand, is freely rotatable (undriven) in this example embodiment. The first-roller-assembly actuator 300a, which includes an electric motor in this example embodiment but may be any other suitable actuator, is operably connected to the first drive roller 310 and the first idle roller 320 (such as via the first-roller-assembly support) and configured to move the first drive roller 310 and the first idle roller 320 in a transverse direction TD that is transverse to (and here, perpendicular to) the movement direction MD relative to the conveyor system (and any load on it), the roll-support assembly 200 (and any roll R thereon), and the second roller assembly 400.

[0014] The second roller assembly 400 manipulates the wrapping material WM during the wrapping process and, after the wrapping process is complete, receives and stores wrapping material WM from the first roller assembly 300 in preparation for the next wrapping process. The second roller assembly 300 includes a cylindrical second drive roller 410, a second- drive-roller actuator 410a, a cylindrical second idle roller 420, a second-roller-assembly actuator 400a, and a second-roller-assembly support (not shown for clarity). The second drive roller 410 and the second idle roller 420 are vertically oriented (into and out of the page from the perspective shown in Figures 1 and 3-16) and rotatably mounted to the second-roller-assemblysupport. A second biasing member (not shown), such as one or more springs, biases the second idle roller 420 into contact with the second drive roller 410. The second-drive-roller actuator 410a, which includes an electric motor in this example embodiment but may be any other suitable actuator, is operably connected to the second drive roller 410 and configured to rotate the second drive roller 410 relative to the second idle roller 420. The second idle roller 420, on the other hand, is freely rotatable (undriven) in this example embodiment. The second-rollerassembly actuator 400a, which includes an electric motor in this example embodiment but may be any other suitable actuator, is operably connected to the second drive roller 410 and the second idle roller 420 (such as via the second-roller-assembly support) in the transverse direction TD relative to the conveyor system (and any load on it), the roll-support assembly 200 (and any roll R thereon), and the first roller assembly 300.

[0015] The gripper assembly grips the wrapping material WM to hold it in place during certain stages of the wrapping process to facilitate forming the loop. The gripper assembly includes a gripper 510 and a gripper actuator 510a. The gripper 510 includes any suitable device, such as a pair of movable fingers, actuatable between a gripping configuration in which the gripper 510 grips the wrapping material WM and a release configuration in which the gripper 510 releases the wrapping material WM. The gripper actuator 510a includes one or more actuators, such as one or more electric motors, configured to: (1) actuate the gripper 510 between its gripping and release configurations; and (2) move the gripper 510 into position so the gripper 510 can grip the wrapping material WM. This embodiment of the gripper assembly includes a single gripper, but other embodiments may include any suitable quantity of grippers, such as one gripper positioned and otherwise configured to grip a top edge of the wrapping material and another gripper positioned and otherwise configured to grip a bottom edge of the wrapping material.

[0016] The adhesive-applicator assembly applies adhesive to a portion of the wrapping material WM to facilitate forming the loop. The adhesive-applicator assembly includes an adhesive applicator 610 and an adhesive-applicator actuator 610a. The adhesive applicator 610 may be any suitable device actuatable to apply any suitable type of adhesive to the wrapping material WM. In this example embodiment, the adhesive applicator 610 includes a tape dispenser configured to apply double-sided adhesive tape to the wrapping material. In other embodiments, the adhesive applicator includes a sprayer or a roller configured to spray liquid adhesive onto thewrapping material. The adhesive-applicator actuator 610a includes one or more actuators configured to: (1) actuate the adhesive applicator 610 to apply the adhesive; and (2) move the adhesive applicator 610 to facilitate the application of the adhesive, which in this example embodiment involves moving the adhesive applicator vertically relative to the conveyor system (and any load on it), the roll-support assembly 200 (and any roll R thereon), the first roller assembly 300, and the second roller assembly 400.

[0017] The cutter assembly cuts the wrapping material WM from the roll R. The cutter assembly includes a cutter 710 and a cutter actuator 710a operably connected to the cutter 710 to actuate the cutter 710 to cut the wrapping material WM. In this example embodiment, the cutter 710 includes a retractable blade housed within the first drive roller 310, and the cutter actuator 710a (which is an electric motor in this example embodiment but may be any suitable actuator) is operably connected to the cutter 710 to project the cutter 710 from the first drive roller 310 to cut the wrapping material WM.

[0018] The sensors S include any suitable sensors (such as encoders) configured to sense rotation of the one or more of the roll R, the first drive roller 310, the first idle roller 320, the second drive roller 410, and the second idle roller 420. In certain embodiments, the sensors include a presence sensor configured to detect whether the wrapping material is extending between the roll and the first drive roller. This presence sensor may include an optical sensor or may include a position sensor operably connected to a dancer roller contacting the wrapping material extending between the roll and the first drive roller.

[0019] The first corner-protector applicator 2000a applies corner protectors CP to the corners of a load at certain points during the wrapping process and holds the corner protectors in place until the wrapping material applied to the load is sufficiently tensioned to hold the corner protectors in place. The first corner-protector applicator 2000a includes a first robotic arm 2100a, a first arm support 2200a, a first rail 2300a, a first corner-protector supply 2400a storing multiple corner protectors CP, and a first arm-support actuator 2500a. The first robotic arm 2100a includes any suitable type of robotic arm including an end effector suitable for removing a corner protector CP from the first corner-protector supply 2400a and holding the corner protector CP. In certain embodiments, the end effector includes a vacuum device. In other embodiments, the end effector includes multiple articulatable fingers.

[0020] The first rail 2300a is positioned adjacent to the conveyor 55 and extends substantially parallel to the conveyor 55 in the movement direction MD. The first arm support 2200a is slidably mounted to the first rail 2300a and configured to translate along the first rail 2300a. The first robotic arm 2100a is mounted to the first arm support 2200a and is translatable along with the first arm support 2200a along the first rail 2300a. The first arm-support actuator 2500a, which is an electric motor (such as a servo motor) in this example embodiment but may be any other suitable actuator in other embodiments, is operably connected to the first arm support 2200a and configured to move the first arm support 2200a and the first robotic arm 2100a along the first rail 2300a, as explained below.

[0021] The second comer-protector applicator 2000b applies corner protectors CP to the corners of a load at certain points during the wrapping process and holds the corner protectors in place until the wrapping material applied to the load is sufficiently tensioned to hold the corner protectors in place. The second corner-protector applicator 2000b includes a second robotic arm 2100b, a second arm support 2200b, a second rail 2300b, a second comerprotector supply 2400b storing multiple corner protectors CP, and a second arm-support actuator 2500b. The second robotic arm 2100b includes any suitable type of robotic arm including an end effector suitable for removing a corner protector CP from the second comer-protector supply 2400b and holding the corner protector CP. In certain embodiments, the end effector includes a vacuum device. In other embodiments, the end effector includes multiple articulatable fingers.

[0022] The second rail 2300b is positioned adjacent to the conveyor 55 on the side opposite the first rail 2300a and extends substantially parallel to the conveyor 55 in the movement direction MD. The second arm support 2200b is slidably mounted to the second rail 2300b and configured to translate along the second rail 2300b. The second robotic arm 2100b is mounted to the second arm support 2200b and is translatable along with the second arm support 2200b along the second rail 2300b. The second arm-support actuator 2500b, which is an electric motor in this example embodiment but may be any other suitable actuator in other embodiments, is operably connected to the second arm support 2200b and configured to move the second arm support 2200b and the second robotic arm 2100b along the second rail 2300b, as explained below.

[0023] The controller 900 includes a processing device communicatively connected to a memory device. The processing device includes any suitable processing device such as, butnot limited to, a general-purpose processor, a special -purpose processor, a digital -si n al 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 memory device includes 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 wrapping system 10 (such as to carry out the wrapping process described below).

[0024] The controller 900 is communicatively and operably connected to the conveyor actuator 55a, the roll actuator 210a, the first-roller-assembly actuator 300a, the first- drive-roller actuator 310a, the second-roller-assembly actuator 400a, the second-drive-roller actuator 410a, the gripper actuator 510a, the adhesive-applicator actuator 610a, the cutter actuator 710a, the sensors S, the first robotic arm 2100a, the second robotic arm 2100b, the first arm-support actuator 2500a, and the second arm-support actuator 2500b to control operation of and receive signals from these components to carry out the wrapping process described below.

[0025] The wrapping system 10 is configured to carry out a wrapping process to apply comer protectors CP to the four vertical corners of a load of goods 1000 and to form a loop 1000s of the wrapping material WM around the load of goods 1000. The wrapping process is described below with reference to Figures 3-16. The load 1000 has a length L, a width W, a leading surface 1000a, a trailing surface 1000b opposite the leading surface 1000a, a first side surface 1000c, and a second side surface lOOOd opposite the first side surface 1000c. The load 1000 has a first leading comer Cl where the leading surface 1000a meets the first side surface 1000c, a second leading comer C2 where the leading surface 1000a meets the second side surface lOOOd, a first trailing corner C3 where the trailing surface 1000b meets the first side surface 1000c, and a second trailing corner C4 wherein the trailing surface 1000b meets the second side surface lOOOd.

[0026] Figure 3 shows the positions and configurations of various components of the wrapping system 10 at the start of the wrapping process. The first arm support 2200a is at a home position near the first corner-protector supply 2400a, and the first robotic arm 2100a ispositioned and otherwise configured so its end effector is positioned to retrieve a corner protector CP from the first corner-protector supply 2400a. The second arm support 2200b is at a home position near the second corner-protector supply 2400b, and the second robotic arm 2100b is positioned and otherwise configured so its end effector is positioned to retrieve a corner protector CP from the second corner-protector supply 2400b. The first drive roller 310 and first idle roller 320 are in a home position in which they are between the roll R and the load 1000. The second drive roller 410 and second idle roller 420 are in a home position on the opposite side of the load 1000 from the first drive and idle rollers and in which they are spaced-apart from the load 1000 in the transverse direction TD. The wrapping material WM extends from the roll R, through the nip between the first drive roller 310 and the first idle roller 320, across the conveyor 55 and in front of the leading surface 1000a of the load 1000, between the nip between the second drive roller 410 and the second idle roller 420, and around the second drive roller 410. The length of wrapping material WM wrapped around the second drive roller 410 is approximately equal to the sum of the length L and half of the width W of the load 1000, though it may be any suitable amount.

[0027] The controller 900 controls the first robotic arm 2100a to retrieve a first leading corner protector CPI from the first corner-protector supply 2400a and to position the first leading comer protector CPI against the first leading corner Cl of the load 1000. The controller 9000 also controls the second robotic arm 2100b to retrieve a second leading corner protector CP2 from the second corner-protector supply 2400b and to position the second leading corner protector CP2 against the second leading corner C2 of the load 1000. Figure 4 shows the first and second robotic arms 2100a and 2100b holding the first and second leading corner protectors CPI and CP2 against the first and second leading corners Cl and C2 of the load 1000, respectively. Although not shown, the end effectors of the robotic arms hold the respective corner protectors near their bottom ends to prevent the robotic arms from interfering with application of the wrapping material around the load.

[0028] The controller 900 controls the conveyor actuator 55a to drive the conveyor 55 to move the load 1000 in the movement direction MD relative to the wrapping machine 100 and the wrapping material WM. While doing so, the controller 900 controls the first robotic arm 2100a and the first arm-support actuator 2500a such that the first leading corner protector CPI moves with the load 1000. In certain embodiments, this results in the first robotic arm 2100areorienting itself and the first arm support 2200a — and the first robotic arm 2100a thereon — moving along the first rail 2100a in the movement direction MD at the same rate as the conveyor 55 moves the load 1000 in the movement direction MD. Simultaneously, the controller 900 controls the second robotic arm 2100b and the second arm-support actuator 2500 such that the second leading corner protector CP2 moves with the load 1000. In certain embodiments, this results in the second robotic arm 2100b reorienting itself and the second arm support 2200b — and the second robotic arm 2100b thereon — moving along the second rail 2100b in the movement direction MD at the same rate as the conveyor 55 moves the load 1000 in the movement direction MD. As shown in Figure 5, first and second leading corner protectors CPI and C2 and the part of the leading surface 1000a between these corner protectors eventually contact the wrapping material WM suspended across the conveyor 55.

[0029] As shown in Figure 6, continued movement of the load 1000 and the first and second leading corner protectors CPI and CP2 results in the comer protectors and the load pulling wrapping material off of the roll R and off of the second drive roller 410, and that wrapping material extending along the first and second side surfaces 1000c and lOOOd, respectively, of the load 1000. Certain types of packaging material, like plastic stretch film and extensible paper packaging material, have some amount of elasticity so they are able to be stretched before application to the load to increase the containment force of the loop (stretched packaging material will squeeze the load tighter than unstretched packaging material). In certain embodiments in which the wrapping material is able to be stretched, during this step the controller 900 controls: (1) the roll actuator 210a so the surface speed of the roll R and the linear speed of the wrapping material WM exiting the roll is less than the linear speed of the load 1000 in the movement direction MD and / or the first-drive-roller actuator 310a so the surface speed of the first drive roller 310 and the linear speed of the wrapping material WM exiting the first drive roller 310 is less than the linear speed of the load 1000 in the movement direction MD; and (2) the second-drive-roller actuator 410a so the surface speed of the second drive roller 410 and the linear speed of the wrapping material WM exiting the second drive roller 410 is less than the linear speed of the load 1000 in the movement direction MD. This speed differential (with the load moving faster than the wrapping material being applied to the load) results in the wrapping material stretching as it is being applied to the load L, with the amount of stretch varying based on the speed differential (larger differential leads to more stretch).

[0030] Once the load 1000 has moved past the first and second drive rollers 310 and 410, as shown in Figure 7, the controller 900 controls the conveyor actuator 55a to stop driving the conveyor 55. At this point, wrapping material WM extends across the leading surface 1000a and along the first and second side surfaces 1000c and lOOOd of the load 1000, and the tension in the applied wrapping material WM is sufficient to hold the first and second leading corner protectors CPI and CP2 in place on the first and second leading corners Cl and C2 of the load 1000. Accordingly, the controller 900 controls the first and second robotic arms 2100a and 2100b to release the first and second leading comer protectors CPI and CP2, respectively, and controls the first and second arm-support actuators 2500a and 2500b to return the first and second arm supports 2200a and 2200b to their respective home positions. In other embodiments, the release of the first and second leading comer protectors may occur before the load has moved past the first and second drive rollers so long as the tension in the applied wrapping material is sufficient to hold the first and second leading comer protectors in place on the respective comers.

[0031] The controller 900 then controls the first robotic arm 2100a to retrieve a first trailing corner protector CP3 from the first comer-protector supply 2400a and to position the first trailing corner protector CP3 against the first trailing corner C3 of the load 1000. The controller 9000 also controls the second robotic arm 2100b to retrieve a second trailing corner protector CP4 from the second corner-protector supply 2400b and to position the second trailing corner protector CP4 against the second trailing comer C4 of the load 1000. Figure 8 shows the first and second robotic arms 2100a and 2100b holding the first and second trailing comer protectors CP3 and CP4 against the first and second trailing corners C3 and C4 of the load 1000, respectively. Although not shown, the end effectors of the robotic arms hold the respective corner protectors near their bottom ends to prevent the robotic arms from interfering with application of the wrapping material around the load.

[0032] As shown in Figure 9, the controller 900 controls the first-roller-assembly actuator 300a to move the first drive roller 310 and the first idle roller 320 in the transverse direction TD from their home position to a sleeving position closer to the second drive roller 410 and the second idle roller 420. During this movement, the first drive roller 310 pulls the wrapping material WM from the roll R and across part of the trailing surface 1000b of the load 1000.

[0033] As shown in Figure 10, the controller 900 then controls the gripper actuator 510a to control the gripper 510 to grip the wrapping material WM near where it exits the first drive roller 310. The gripper 510 is not shown outside of Figures 10-13 for clarity.

[0034] As shown in Figure 11, the controller 900 controls the adhesive-applicator actuator 610a to move and otherwise control the adhesive applicator 610 to apply adhesive, which is double-sided adhesive tape T in this example embodiment (shown with an exaggerated thickness in Figure 12 for clarity and not shown in the remaining Figures), to a portion of the wrapping material WM extending across the trailing surface 1000b of the load 1000. In this example embodiment, the adhesive applicator 610 applies the adhesive to the wrapping material near the midpoint of the width of the load 1000.

[0035] As shown in Figure 12, the controller 900 controls the cutter actuator 710a to actuate the cutter 710 to cut the wrapping material WM from the roll R. In this example embodiment, the controller 900 controls the cutter actuator 710a to project the cutter 710 from the first drive roller 710 to cut the wrapping material WM from the roll R. After cutting, the first drive roller 310 and the first idle roller 320 continue to hold the wrapping material WM extending from the roll R. The cutter 710 is not shown in any other Figures for clarity.

[0036] As shown in Figure 13, the controller 900 controls the first-roller-assembly actuator 300a to move the first drive roller 310 and the first idle roller 320 in the transverse direction TD from their sleeving position back to their home position near the roll R. In some embodiments, while doing so, the controller 900 controls the roll actuator 210a to rotate the roll R to wind any slack wrapping material WM onto the roll R. The controller 900 controls the second-roller-assembly actuator 400a to move the second drive roller 410 and the second idle roller 420 in the transverse direction TD from their home position to a sleeving position closer to the first drive roller 310 and the second idle roller 320. During this movement, the rest of the wrapping material WM on the second drive roller 410 unwinds and extends across the trailing surface 1000b of the load 1000. The second drive roller 410 is positioned relative to the load 1000 so the second drive roller 410 forces part of the unwound wrapping material WM against the adhesive (here, the tape T, which is no longer shown for clarity), which adheres the wrapping material WM to itself and completes formation of the loop 1000s around the load L.

[0037] The tension in the loop 1000s is sufficient to hold the first and second trailing corner protectors CP3 and CP4 in place on the first and second trailing corners C3 and C4 of theload 1000. Accordingly, the controller 900 controls the first and second robotic arms 2100a and 2100b to release the first and second trailing corner protectors CP3 and CP4, respectively, and controls the first and second arm-support actuators 2500a and 2500b to return the first and second arm supports 2200a and 2200b to their respective home positions, as shown in Figure 14. Wrapping material WM is then wrapped around the second drive roller 410 in preparation for the next wrapping cycle. Specifically, as shown in Figure 14, the first-roller-assembly actuator 300a and the second-roller-assembly actuator 400a move the first drive and idle rollers 310 and 320 and the second drive and idle rollers 410 and 420, respectively, to respective reloading positions adjacent one another. As this occurs, the controller 900 controls the roll actuator 210a to rotate the roll R to unwind wrapping material WM from the roll R to compensate for the movement of the first drive and idle rollers 310 and 320. The controller 900 also controls the conveyor actuator 55a to drive the conveyor 55 to move the loopd load 1000 in the movement direction MD.

[0038] As shown in Figure 15, with the rollers in their reloading positions, the controller 900 controls: (1) the roll actuator 210a to unwind wrapping material WM from the roll R; (2) the first-drive-roller actuator 310a to feed the wrapping material WM to the second drive and idle rollers 410 and 420; and (3) the second-drive-roller actuator 410a to rotate the second drive roller 410 so the wrapping material WM wraps around the second drive roller 410. The controller 900 stops the actuators once the length of wrapping material WM wrapped around the second drive roller 410 is approximately equal to the sum of the length and half of the width of incoming load 1500 (Figure 16). In certain embodiments, the controller 900 controls the linear speeds of the roll R and / or the drive rollers 310 and 410 to prestretch the wrapping material WM during this reloading step. For instance, in one embodiment, the controller controls the roll actuator and the first-drive-roller actuator to prestretch the wrapping material between the roll and the first drive roller. In another embodiment, the controller controls the first-drive-roller actuator and the second-drive-roller actuator to prestretch the wrapping material as it moves between the two drive rollers.

[0039] As shown in Figure 16, the controller 900 then controls the first-rollerassembly actuator 300a and the second-roller-assembly actuator 400a move the first drive and idle rollers 310 and 320 and the second drive and idle rollers 410 and 420, respectively, back to their respective home positions in preparation for the incoming load 2000.

[0040] The packaging material may be any suitable type of packaging material, such as kraft paper, micro-creped paper, plastic film (such as stretch film), narrow strap (such as polypropylene strap, PET strap, or paper strap), and the like. The packaging material may be any suitable width and any suitable thickness and may or may not be stretchable depending on the embodiment. In embodiments in which plastic stretch film is used as the packaging material, the plastic stretch film may be sealed to itself (such as via any of a variety of different heat-sealing methods) to form the loop around the load. In embodiments in which strap is used as the packaging material, the strap may be joined to itself (such as via any of a variety of different methods like hot-knife welding or friction welding) to form the loop around the load.

[0041] In the embodiment described above, each corner-protector applicator is associated with a single corner-protector supply storing a single type of corner protector that may be retrieved by the robotic arm. In other embodiments, each comer-protector applicator is associated with multiple corner-protector supplies each storing different types of corner protectors, such as comer protectors having different heights, different leg lengths, different thicknesses, different shapes, and / or different materials. In these embodiments, the robotic arm may retrieve a corner protector from any of the multiple corner-protector supplies depending on the requirements for the load.

[0042] In the embodiment described above, each corner-protector applicator is configured to apply only one corner protector to the load — either to its leading comer or to its trailing comer — at a given point in time. In other embodiments, each corner-protector applicator is configured to retrieve two corner protectors substantially simultaneously and substantially simultaneously apply the corner protectors to the leading and railing comers of the load.

[0043] In certain embodiments, additional packaging material is applied to the load after the loop of packaging material is formed to hold the corner protectors in place. For instance, the load (including the corner protectors and loop) may be subsequently wrapped with plastic stretch film by a ring-type (or other type) wrapping machine, wrapped with a hood of tubular plastic film by a stretch-hooding machine, or strapped with one or more straps by a strapping machine.

Claims

Claims1. A method for applying a loop of packaging material to a load, the method comprising: positioning a first comer protector on a leading vertical comer of the load; moving the first corner protector and the load in a movement direction such that the leading corner protector and a leading surface of the load engage packaging material extending across a path of the load; continue moving the first comer protector and the load such that the packaging material extends at least partially along opposing first and second side surfaces of the load; positioning a second corner protector on a trailing vertical corner of the load; and applying the packaging material to a trailing surface of the load to form a loop of packaging material around the load, wherein the loop of packaging material, at least in part, holds the first corner protector on the leading vertical corner of the load and holds the second corner protector on the trailing vertical corner of the load.

2. The method of claim 1, further comprising releasing the first corner protector before positioning the second comer protector on the trailing vertical corner of the load.

3. The method of claim 2, further comprising releasing the first corner protector after the packaging material extends at least partially along the first and second side surfaces of the load.

4. The method of claim 2, further comprising releasing the second corner protector after at least partially applying the packaging material to the trailing surface of the load.

5. The method of claim 1, further comprising retrieving, via a robotic arm, the first corner protector from a corner-protector supply, wherein positioning the first corner protector on the leading vertical corner of the load comprises controlling the robotic arm to position the first corner protector on the leading vertical corner of the load.

6. The method of claim 5, wherein moving the first corner protector in the movement direction comprises at least one of: (1) manipulating the robotic arm; and (2) translating the robotic arm.

7. The method of claim 6, wherein translating the robotic arm comprises moving the robotic arm along a rail that extends substantially parallel to the movement direction.

8. The method of claim 5, further comprising retrieving, via the robotic arm, the second comer protector from the corner-protector supply, wherein positioning the second comer protector on the trailing vertical comer of the load comprises controlling the robotic arm to position the second comer protector on the trailing vertical corner of the load.

9. The method of claim 8, further comprising stopping movement of the load in the movement direction before positioning the second corner protector on the trailing corner of the load.

10. The method of claim 1, wherein the packaging material comprises one of: plastic stretch film, paper packaging material, and strap.

11. A method for applying a loop of packaging material to a load, the method comprising: positioning a first leading corner protector on a first leading vertical corner of the load; positioning a second leading comer protector on a second leading vertical comer of the load; moving the first and second leading corner protectors and the load in a movement direction such that the first and second leading comer protectors and a leading surface of the load engage packaging material extending across a path of the load; continue moving the first and second leading corner protectors and the load such that the packaging material extends at least partially along opposing first and second side surfaces of the load; positioning a first trailing comer protector on a first trailing vertical corner of the load;positioning a second trailing corner protector on a second trailing vertical comer of the load; and applying the packaging material to a trailing surface of the load to form a loop of packaging material around the load, wherein the loop of packaging material, at least in part, holds the first leading corner protector on the first leading vertical corner of the load, holds the second leading corner protector on the second leading vertical corner of the load, holds the first trailing corner protector on the first trailing vertical comer of the load, and holds the second trailing corner protector on the second trailing vertical corner of the load.

12. The method of claim 11, further comprising substantially simultaneously positioning the first and second leading corner protectors on the first and second leading vertical corners of the load, respectively.

13. The method of claim 11, further comprising substantially simultaneously positioning the first and second trailing comer protectors on the first and second trailing vertical corners of the load, respectively.

14. The method of claim 11, further comprising releasing the first and second leading corner protectors after the packaging material extends at least partially along the first and second side surfaces of the load.

15. The method of claim 14, further comprising releasing the first and second trailing corner protectors after at least partially applying the packaging material to the trailing surface of the load.

16. The method of claim 11, further comprising: retrieving, via a first robotic arm, the first leading corner protector from a first comerprotector supply; and retrieving, via a second robotic arm, the second leading corner protector from a second corner-protector supply,wherein positioning the first leading corner protector on the first leading vertical corner of the load comprises controlling the first robotic arm to position the first leading corner protector on the first leading vertical comer of the load, wherein positioning the second leading corner protector on the second leading vertical corner of the load comprises controlling the second robotic arm to position the second leading corner protector on the second leading vertical comer of the load.

17. The method of claim 16, wherein moving the first and second leading comer protectors in the movement direction comprises at least one of: (1) manipulating one or both of the first and second robotic arms; and (2) translating one or both of the first and second robotic arms.

18. The method of claim 16, further comprising: retrieving, via the first robotic arm, the first trailing corner protector from the first comerprotector supply; and retrieving, via the second robotic arm, the second trailing comer protector from the second corner-protector supply, wherein positioning the first trailing corner protector on the first trailing vertical corner of the load comprises controlling the first robotic arm to position the first trailing corner protector on the first trailing vertical comer of the load, wherein positioning the second trailing corner protector on the second trailing vertical corner of the load comprises controlling the second robotic arm to position the second trailing corner protector on the second trailing vertical corner of the load.

19. The method of claim 18, further comprising stopping movement of the load in the movement direction before positioning the first and second trailing corner protectors on the first and second trailing corners of the load.

20. The method of claim 18, further comprising: releasing the first and second leading corner protectors after the packaging material extends at least partially along the first and second side surfaces of the load; andreleasing the first and second trailing corner protectors after at least partially applying the packaging material to the trailing surface of the load.

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