Abstract: A robotic containerization and palletizing system having a multiple-fingered end effector. In one embodiment, the system carries out a method of loading a tray in a container where the method includes creating a cell with a plurality of bays; assigning each bay a location; moving trays through the cell along a path; grasping a tray off the path with a robot positioned above the path; moving the robot, with the grasped tray, to the location of one bay; and instructing the robot to release the tray at the location of the one bay.

Abstract: A robotic containerization and palletizing system having a multiple-fingered end effector. The system includes a frame that defines one or more cells. Each cell has one gantry-type robot, which is mounted in a set of tracks on top of the frame. The robot is movable along two axes and has an arm to which the end effector is mounted. The end effector is designed to grasp trays, tubs, and similar items from a conveyor system running through the cell and load them in a cart or on a pallet. The items are gripped by two sets of fingers. One set of fingers may be mounted to a first plate and another set of fingers may be mounted to a carriage that moves in a horizontal direction, either toward or away from the first set of fingers. Each finger has a main shaft and a bent tip. The shafts are rotatable such that the tips can be moved underneath or out from under a load, depending upon whether a pick-up or drop-off operation is being performed.

Abstract: A robotic containerization and palletizing system having a multiple-fingered end effector. The system includes a frame that defines one or more cells. Each cell has one gantry-type robot, which is mounted in a set of tracks on top of the frame. The robot is movable along two axes and has an arm to which the end effector is mounted. The end effector is designed to grasp trays, tubs, and similar items from a conveyor system running through the cell and load them in a cart or on a pallet. The items are gripped by two sets of fingers. One set of fingers may be mounted to a first plate and another set of fingers may be mounted to a carriage that moves in a horizontal direction, either toward or away from the first set of fingers. Each finger has a main shaft and a bent tip. The shafts are rotatable such that the tips can be moved underneath or out from under a load, depending upon whether a pick-up or drop-off operation is being performed.

Abstract: A method of handling an object using a robot end effector. The method includes providing a robot having an end effector supporting a pair of carriages, providing a pair of fingers for each carriage, moving the end effector over an object, grasping an object with the fingers, moving the object with the end effector to a container, and depositing the object by counter-rotating the pairs of fingers. One or both of the carriages is movable toward the other carriage to engage objects on a conveyor system with the fingers. The robot moves the end effector between the conveyor system and shipping containers for shipping the objects. Because the pairs of fingers counter-rotate, the friction forces between each finger and the tray is offset by the friction forces between the other finger in the pair and the tray. The improved handling method thereby maintains objects substantially in the desired stacking orientation within the shipping container. Preferably, an actuator is provided for each finger.

Abstract: A method of handling an object using a robot end effector. The method includes providing a robot having an end effector supporting a pair of carriages, providing a pair of fingers for each carriage, moving the end effector over an object, grasping an object with the fingers, moving the object with the end effector to a container, and depositing the object by counter-rotating the pairs of fingers. One or both of the carriages is movable toward the other carriage to engage objects on a conveyor system with the fingers. The robot moves the end effector between the conveyor system and shipping containers for shipping the objects. Because the pairs of fingers counter-rotate, the friction forces between each finger and the tray is offset by the friction forces between the other finger in the pair and the tray. The improved handling method thereby maintains objects substantially in the desired stacking orientation within the shipping container. Preferably, an actuator is provided for each finger.

Abstract: An improved end effector for use with a robot includes a pair of carriages. Each carriage supports a pair of fingers and at least one actuator. Each actuator is interconnected with the associated pair of fingers to counter-rotate the fingers. One or both of the carriages is movable toward the other carriage to engage trays on a conveyor system with the fingers. The robot moves the end effector between the conveyor system and shipping containers for shipping the trays. Because the pairs of fingers counter-rotate, the friction forces between each finger and the tray is offset by the friction forces between the other finger in the pair and the tray. The improved end effector thereby maintains trays substantially in the desired stacking orientation within the shipping container. Preferably, an actuator is provided for each finger. A change-out mechanism may also be provided to facilitate replacing the fingers.

Abstract: A docking station for a robotic mail tray loading system includes a ground plate that is mounted to the floor of the building in which the robotic mail tray loading system is housed. The ground plate has first and second wheel-retaining recesses that preferably include ramped surfaces to accommodate wheels of mail carts. A plurality of guide plates are positioned to locate one pallet or two mail carts in the docking station at a time. The docking station also includes a plurality of sensors that sense the presence or absence of a pallet or cart in the docking station and that sense the type of cart present at the cart docking station.

Abstract: A device for mechanically gripping, transporting, loading and unloading cylindrical containers of various sizes for attachment to a robotic arm. The containers may be bottles including drinking water bottles. The device includes a plurality of gripping mechanisms for gripping the containers. Support pins are also provided for supporting the rotational motion of full bottles. A system for efficiently removing empty containers from racks and simultaneously loading full containers is also disclosed.

Abstract: An end effector for use with a robot and capable of removing cases from a stack of cases and emptying the selected case of substantially flat, folded articles. The end effector includes a main body designed to be coupled to the robot. A case gripper is mounted on the bottom of the main body. A flattened articles gripper is also coupled to the main body and includes a vacuum chamber with two blades. A dunnage gripper is mounted on one of the sides of the main body. In use, the case gripper picks a full case from a pallet of cases and moves that case to an unloading station. There, the end effector is rotated so that the blades of the flattened articles gripper can be inserted into the case. With the blades inserted, vacuum is supplied to the flattened articles gripper to hold the articles against the gripper. Then, the end effector with the articles is moved to a regripping station where the articles are temporarily placed and regripped.