SYSTEM AND METHOD FOR FORMING AN ARTICLE ARRAY
An apparatus for forming an article array including a head having at least one pair of opposed substantially planar gripping members, adapted for selectively securing a row of articles therebetween. Each pair of gripping members includes a first gripping member movable in a lateral direction parallel to a support surface and a second gripping member movable between extended and raised positions relative to the first gripping member. In response to the pair of gripping members at least partially laterally surrounding the row of articles, a movement of the second gripping member from the extended position to the raised position results in the second gripping member being sufficiently moved in a direction perpendicular to and away from the support surface, permitting the first gripping member to slidably move the row of articles in the lateral direction along the support surface without the second gripping member contacting the row of article.
The present invention is directed to a system and method for forming an article array for ultimately palletizing articles, and specifically to a system and method for forming an article array for ultimately palletizing articles while using the same head for differently sized articles.
BACKGROUND OF THE INVENTIONWhen large numbers of stackable articles must be transported in large quantities to another location, especially when the article is small, the article may be packaged in a container to protect the article during shipping of the container. Alternately, to reduce the amount of handling required, the articles may be arranged in a tight grouping, or array of articles. Each array of articles can form a layer of articles that can be stacked on a pallet having a footprint which can be accommodated by freight hauling compartments, e.g., for truck, rail, sea or air vessels.
Palletizing articles is becoming increasingly automated in manufacturing facilities, wherein articles are moved via a conveyor, which articles are manipulated by robots onto pallets using specialized end of arm tooling or article head usable only on one article having a particular size/shape. That is, additional article heads must be specially constructed for each different article to be manipulated, which can be expensive, and could disrupt operations until a compatible article head is made available. Moreover, this operating limitation could prevent the ability to accommodate “special one-time runs” for a small amount of uniquely sized articles, such as for reasons including cost and time delays in obtaining a specialized head.
What is needed is an apparatus and method for palletizing articles that does not suffer from these drawbacks.
SUMMARY OF THE INVENTIONThe present invention relates to an apparatus for forming an article array including a head having at least one pair of opposed substantially planar gripping members, each pair of gripping members adapted for selectively securing a row of articles therebetween for transporting the row of articles between a first location having a horizontal first support surface and a second location having a horizontal second support surface. Each pair of gripping members includes a first gripping member movable in a lateral direction parallel to the first support surface and the second support surface and a second gripping member movable between an extended position and a raised position relative to the first gripping member. In response to the pair of gripping members at least partially laterally surrounding the row of articles, a movement of the second gripping member from the extended position to the raised position results in the second gripping member being sufficiently moved in a direction perpendicular to and away from at least one of the first support surface and the second support surface, permitting the first gripping member to slidably move the row of articles in the lateral direction along the at least one of the first support surface and the second support surface without the second gripping member contacting the row of articles.
The present invention further relates to a method for building an article array comprised of (n) rows of articles, the steps including:
(a) positioning a head having a pair of opposed substantially planar gripping members such that the pair of gripping members at least partially laterally surrounds a first row of first articles at a first location, the first location having a horizontal first support surface for supporting the first row of first articles;
(b) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the first row of first articles;
(c) transporting the first row of first articles from the first location to a second location, the second location having a horizontal second support surface for supporting the first row of first articles;
(d) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the first row of first articles;
(e) positioning the head such that the pair of gripping members at least partially laterally surrounds a second row of first articles at the first location;
(f) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the second row of first articles;
(g) transporting the second row of first articles from the first location to the second location in close proximity to the first row of first articles, the first row of first articles and the second row of first articles having one of at least a first arrangement, a second arrangement, and a third arrangement;
(h) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the second row of first articles;
(i) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface in response to the first row of first articles and the second row of first articles having the first arrangement or the second arrangement, in response to the first row of first articles and the second row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface is optional;
(j) moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the second row of first articles to move in the lateral direction toward the first row of first articles in response to the first row of first articles and the second row of first articles having the first arrangement or the second arrangement, the first row of first articles and the second row of first articles forming a partial article array, in response to the first row and the second row of first articles having the third arrangement, moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the second row of first articles to move in the lateral direction toward the first row of first articles is optional;
(k) repeating steps (e)-(j) until a partial article array is formed including an (n−1) row of first articles;
(l) positioning the head such that the pair of gripping members at least partially laterally surrounds an (n) row of first articles at the first location;
(m) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (n) row of first articles;
(n) transporting the (n) row of first articles from the first location to the second location in close proximity to the partial article array including the (n−1) row of first articles;
(o) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (n) row of first articles;
(p) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface in response to the partial article array including the (n−1) row of first articles and the (n) row of first articles having the first arrangement or the second arrangement, in response to the partial article array including the (n−1) row of first articles and the (n) row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface is optional; and
(q) moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the (n) row of first articles to move in the lateral direction toward the partial article array including the (n−1) row of first articles in response to the partial article array including the (n−1) row of first articles and the (n) row of first articles having the first arrangement or the second arrangement, the partial article array including the (n−1) row of first articles and the (n) row of first articles forming the article array.
In response to the partial article array including the (n−1) row of first articles and the (n) row of first articles having the third arrangement, moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the (n) row of first articles to move in the lateral direction toward the partial article array including the (n−1) row of first articles is optional, the partial article array including the (n−1) row of first articles and the (n) row of first articles forming the article array.
The present invention yet further relates to a method of building a pallet comprised of article arrays, each article array having a plurality of article rows comprised of first articles extending in one of an x-direction and a y-direction within a rectangular areal footprint in the x-direction and the y-direction, including:
(a) inputting parameters including a height dimension, a width dimension and a length dimension of a first article, a dimension of the rectangular areal footprint in the x-direction, a dimension of the rectangular areal footprint in the y-direction, a dimension of a width of article rows to be provided from an article row source, a type of arrangement to be used between adjacent article rows for building the first article arrays, the direction (x-direction or y-direction) and length dimension of the article rows;
(b) in response to the parameters being input, a controller controls a number of articles contained in a first row of first articles, and each subsequent row of first articles, at a first location having a horizontal first support surface for supporting each row of first articles;
(c) positioning a head having a pair of opposed substantially planar gripping members such that the pair of gripping members at least partially laterally surrounds the first row of first articles at the first location;
(d) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the first row of first articles;
(e) transporting the first row of first articles from the first location to a second location, the second location having a horizontal second support surface for supporting the first row of first articles and each subsequent row of first articles, the first row of first articles positioned in the inputted direction;
(f) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the first row of first articles;
(g) positioning the head such that the pair of gripping members at least partially laterally surrounds a second row of first articles at the first location;
(h) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the second row of first articles;
(i) transporting the second row of first articles from the first location to the second location in close proximity to the first row of first articles, the first row of first articles and the second row of first articles having an inputted type of arrangement of one of at least a first arrangement, a second arrangement and a third arrangement;
(j) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the second row of first articles;
(k) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface in response to the first row of first articles and the second row of first articles having the first arrangement or the second arrangement, in response to the first row of first articles and the second row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface is optional;
(l) moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the second row of first articles to move in the lateral direction toward the first row of first articles in response to the first row of first articles and the second row of first articles having the first arrangement or the second arrangement, the first row of first articles and the second row of first articles forming a first partial article array, in response to the first row and the second row of first articles having the third arrangement, moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the second row of first articles to move in the lateral direction toward the first row of first articles is optional;
(m) repeating steps (g)-(l) until a first partial article array is formed including an (n−1) row of first articles;
(n) positioning the head such that the pair of gripping members at least partially laterally surrounds an (n) row of first articles at the first location;
(o) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (n) row of first articles;
(p) transporting the (n) row of first articles from the first location to the second location in close proximity to the first partial article array including the (n−1) row of first articles;
(q) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (n) row of first articles;
(r) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface in response to the first partial article array including the (n−1) row of first articles and the (n) row of first articles having the first arrangement or the second arrangement, in response to the first partial article array including the (n−1) row of first articles and the (n) row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface is optional;
(s) moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the (n) row of first articles to move in the lateral direction toward the first partial article array including the (n−1) row of first articles in response to the first partial article array including the (n−1) row of first articles and the (n) row of first articles having the first arrangement or the second arrangement, the first partial article array including the (n−1) row of first articles and the (n) row of first articles forming a first article array,
in response to the first partial article array including the (n−1) row of first articles and the (n) row of first articles having the third arrangement, moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the (n) row of first articles to move in the lateral direction toward the first partial article array including the (n−1) row of first articles is optional, the first partial article array including the (n−1) row of first articles and the (n) row of first articles forming the first article array;
(t) moving the head to a third location to pick up one of a slip sheet and a tray;
(u) placing the one of the slip sheet and the tray over the first article array;
(v) positioning the head such that the pair of gripping members at least partially laterally surrounds an (n+1) row of first articles at the first location;
(w) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (n+1) row of first articles;
(x) transporting the (n+1) row of first articles from the first location to a fourth location, the fourth location being the one of the slip sheet and the tray having a horizontal third support surface for supporting the (n+1) row of first articles and each subsequent row of first articles;
(y) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (n+1) row of first articles;
(z) positioning the head such that the pair of gripping members at least partially laterally surrounds an (n+2) row of first articles at the first location;
(aa) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (n+2) row of first articles;
(ab) transporting the (n+2) row of first articles from the first location to the fourth location in close proximity to the (n+1) row of first articles, the (n+1) row of first articles and the (n+2) row of first articles having the inputted type of arrangement of one of at least the first arrangement, the second arrangement, and the third arrangement;
(ac) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (n+2) row of first articles;
(ad) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the third support surface in response to the (n+1) row of first articles and the (n+2) row of first articles having the first arrangement or the second arrangement, in response to the (n+1) row of first articles and the (n+2) row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the third support surface is optional;
(ae) moving the head in a lateral direction parallel to the third support surface such that the other one gripping member of the pair of gripping members urging the (n+2) row of first articles to move in the lateral direction toward the (n+1) row of first articles in response to the (n+1) row of first articles and the (n+2) row of first articles having the first arrangement or the second arrangement, the (n+1) row of first articles and the (n+2) row of first articles forming a second partial article array,
in response to the (n+1) row and the (n+2) row of first articles having the third arrangement, moving the head in the lateral direction parallel to the third support surface such that the other one gripping member of the pair of gripping members urging the (n+2) row of first articles to move in the lateral direction toward the (n+1) row of first articles is optional;
(af) repeating steps (z)-(ae) until a second partial article array is formed including a (2n−1) row of first articles;
(ag) positioning the head such that the pair of gripping members at least partially laterally surrounds a (2n) row of first articles at the first location;
(ah) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (2n) row of first articles;
(ai) transporting the (2n) row of first articles from the first location to the fourth location in close proximity to the second partial article array including the (2n−1) row of first articles;
(aj) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (2n) row of first articles;
(ak) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the third support surface in response to the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles having the first arrangement or the second arrangement, in response to the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the third support surface is optional;
(al) moving the head in a lateral direction parallel to the third support surface such that the other one gripping member of the pair of gripping members urging the (2n) row of first articles to move in the lateral direction toward the second partial article array including the (2n−1) row of first articles in response to the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles having the first arrangement or the second arrangement, the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles forming a second article array,
in response to the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles having the third arrangement, moving the head in a lateral direction parallel to the third support surface such that the other one gripping member of the pair of gripping members urging the (2n) row of first articles to move in the lateral direction toward the second partial article array including the (2n−1) row of first articles is optional, the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles forming the second article array.
(am) moving the head to a fourth location to pick up one of a top sheet and a tray; and
(an) placing the one of the top sheet and the tray over the second article array.
Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
DETAILED DESCRIPTION OF THE INVENTIONThe present invention includes a system and method for constructing palletized articles 10 from article arrays 16, which article arrays include a first article array 44 and a second article array 46 as shown in
The term “article array,” “article layer” and the like may be used interchangeably.
The terms “building” “constructing” and “forming” and the like as it pertains to any of article layers, article arrays and palletized articles may be used interchangeably.
The terms “article array 16,” “article array 44,” “first article array 44,” “article array 46,” “second article array 46” and the like may generally refer to an article array, although (first) article array 44 and (second) article array 46 may also refer to the first two article arrays of a palletized article, such as depicted in
As shown in
Optionally, as shown in
In contrast to
Optionally, as shown in
As shown in
As shown collectively in
As further shown in
As further collectively shown in
As a result of the novel features of the article handling head 90 (
Each rod of actuator 138 is oriented generally parallel to a guide rod 143 of a corresponding guide rod assembly 144 (
Moreover, as a result of operator interface 77 (
The operation of the robotic palletizing cell 70 (
Once article row 148 is collected at and supported by a horizontal surface of collection area 80, as shown in
Once gripping members 98, 100, as shown in
For purposes of clarity and brevity, article rows formed on and supported by collection area 80 will continue to be identified as article row 148, with the article rows 148 transported from collection area 80 being re-identified upon being moved to, placed on, and supported by the horizontal surface of stacking area 72 of the robotic palletizing cell 70 (
Once rows A, B are arranged as shown in
Once gripping member 98 is raised in a direction, such as a vertical direction that is perpendicular to and away from the support surface of stacking area 72 as shown in
Irrespective of head 90 and rows A, B being arranged as shown in one of
Once rows A, B, C are arranged as shown in
Once gripping member 98 is raised in a direction, such as a vertical direction that is perpendicular to and away from the support surface of stacking area 72 as shown in
It is to be understood that the above steps for rows A-C are repeated for chronologically increasing article rows through row N, in which the arrangement and construction of
Once article array 44 has been constructed, head 90 utilizes cover handling device 146 in a manner previously discussed and partially shown in
Once covering 18 has been applied over article array 44, article array 46 (
Once all article rows have been constructed, head 90 utilizes covering handling device 136 (
In one embodiment, article conveyor 78 may include a second collection area 164. In one embodiment, the palletizing cell may include a second article conveyor 166 having a collection area 168 that is provided articles from an article row source 170.
It is to be understood that the article handling head which is usable for building an article array from rows of first articles, each first article having a first height, a first width, and a first length, is also usable, without requiring a change-out of or modification of components of the head, for building an article array from rows of second articles, with each second article having a second height, a second width, and a second length, wherein at least one of the second height, the second width, and the second length of the second articles is different from the first height, the first width, and the first length of the first articles.
In one embodiment, the operator may also be provided with an opportunity to input a height of the palletized articles that is different from the maximum height, if desired.
In one embodiment, instead of the operator being prompted to input all parameters, such as the article array arrangement, or direction of the article rows, the operator may be prompted to input fewer parameters, such as the size parameters of the article to be processed into a palletized article.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims
1. An apparatus for forming an article array comprising:
- a head having at least one pair of opposed substantially planar gripping members, each pair of gripping members adapted for selectively securing a row of articles therebetween for transporting the row of articles between a first location having a horizontal first support surface and a second location having a horizontal second support surface;
- each pair of gripping members comprising: a first gripping member movable in a lateral direction parallel to the first support surface and the second support surface; and a second gripping member movable between an extended position and a raised position relative to the first gripping member, wherein in response to the pair of gripping members at least partially laterally surrounding the row of articles, a movement of the second gripping member from the extended position to the raised position results in the second gripping member being sufficiently moved in a direction perpendicular to and away from at least one of the first support surface and the second support surface, permitting the first gripping member to slidably move the row of articles in the lateral direction along the at least one of the first support surface and the second support surface without the second gripping member contacting the row of articles.
2. The apparatus of claim 1, wherein the first gripping member has a compliant surface facing the second gripping member.
3. The apparatus of claim 1, wherein the first gripping member is movable in the lateral direction relative to the second gripping member.
4. The apparatus of claim 1, wherein the head further comprises a device for handling one of a slip sheet and tray.
5. The apparatus of claim 1, wherein the head further comprises a device for handling a top frame and a pallet.
6. A method for building an article array comprised of (n) rows of articles, the steps comprising:
- (a) positioning a head having a pair of opposed substantially planar gripping members such that the pair of gripping members at least partially laterally surrounds a first row of first articles at a first location, the first location having a horizontal first support surface for supporting the first row of first articles;
- (b) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the first row of first articles;
- (c) transporting the first row of first articles from the first location to a second location, the second location having a horizontal second support surface for supporting the first row of first articles;
- (d) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the first row of first articles;
- (e) positioning the head such that the pair of gripping members at least partially laterally surrounds a second row of first articles at the first location;
- (f) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the second row of first articles;
- (g) transporting the second row of first articles from the first location to the second location in close proximity to the first row of first articles, the first row of first articles and the second row of first articles having one of at least a first arrangement, a second arrangement, and a third arrangement;
- (h) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the second row of first articles;
- (i) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface in response to the first row of first articles and the second row of first articles having the first arrangement or the second arrangement, wherein in response to the first row of first articles and the second row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface is optional;
- (j) moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the second row of first articles to move in the lateral direction toward the first row of first articles in response to the first row of first articles and the second row of first articles having the first arrangement or the second arrangement, the first row of first articles and the second row of first articles forming a partial article array, wherein in response to the first row and the second row of first articles having the third arrangement, moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the second row of first articles to move in the lateral direction toward the first row of first articles is optional;
- (k) repeating steps (e)-(j) until a partial article array is formed including an (n−1) row of first articles;
- (l) positioning the head such that the pair of gripping members at least partially laterally surrounds an (n) row of first articles at the first location;
- (m) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (n) row of first articles;
- (n) transporting the (n) row of first articles from the first location to the second location in close proximity to the partial article array including the (n−1) row of first articles;
- (o) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (n) row of first articles;
- (p) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface in response to the partial article array including the (n−1) row of first articles and the (n) row of first articles having the first arrangement or the second arrangement, wherein in response to the partial article array including the (n−1) row of first articles and the (n) row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface is optional; and
- (q) moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the (n) row of first articles to move in the lateral direction toward the partial article array including the (n−1) row of first articles in response to the partial article array including the (n−1) row of first articles and the (n) row of first articles having the first arrangement or the second arrangement, the partial article array including the (n−1) row of first articles and the (n) row of first articles forming the article array,
- wherein in response to the partial article array including the (n−1) row of first articles and the (n) row of first articles having the third arrangement, moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the (n) row of first articles to move in the lateral direction toward the partial article array including the (n−1) row of first articles is optional, the partial article array including the (n−1) row of first articles and the (n) row of first articles forming the article array.
7. The method of claim 6, wherein the second location is a container having an open top for receiving the article array.
8. The method of claim 6, wherein the first arrangement of adjacent rows of first articles and the second row of first articles is a nested arrangement, the second arrangement of adjacent rows of first articles is a non-nested, closely spaced arrangement, and the third arrangement of adjacent rows of first articles is a non-nested, non-closely spaced arrangement.
9. The method of claim 6, wherein the head usable for building the article array from rows of first articles, each first article having a first height, a first width, and a first length, is also usable, without requiring a change-out of or modification of components of the head, for building an article array from rows of second articles, with each second article having a second height, a second width, and a second length, wherein at least one of the second height, the second width, and the second length of the second articles being different from the first height, the first width, and the first length of the first articles.
10. A method of building a pallet comprised of article arrays, each article array having a plurality of article rows comprised of first articles extending in one of an x-direction and a y-direction within a rectangular areal footprint in the x-direction and the y-direction, comprising:
- (a) inputting parameters including a height dimension, a width dimension and a length dimension of a first article, a dimension of the rectangular areal footprint in the x-direction, a dimension of the rectangular areal footprint in the y-direction, a dimension of a width of article rows to be provided from an article row source, a type of arrangement to be used between adjacent article rows for building the first article arrays, the direction (x-direction or y-direction) and length dimension of the article rows;
- (b) in response to the parameters being input, a controller controls a number of articles contained in a first row of first articles, and each subsequent row of first articles, at a first location having a horizontal first support surface for supporting each row of first articles;
- (c) positioning a head having a pair of opposed substantially planar gripping members such that the pair of gripping members at least partially laterally surrounds the first row of first articles at the first location;
- (d) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the first row of first articles;
- (e) transporting the first row of first articles from the first location to a second location, the second location having a horizontal second support surface for supporting the first row of first articles and each subsequent row of first articles, the first row of first articles positioned in the inputted direction;
- (f) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the first row of first articles;
- (g) positioning the head such that the pair of gripping members at least partially laterally surrounds a second row of first articles at the first location;
- (h) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the second row of first articles;
- (i) transporting the second row of first articles from the first location to the second location in close proximity to the first row of first articles, the first row of first articles and the second row of first articles having an inputted type of arrangement of one of at least a first arrangement, a second arrangement and a third arrangement;
- (j) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the second row of first articles;
- (k) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface in response to the first row of first articles and the second row of first articles having the first arrangement or the second arrangement, wherein in response to the first row of first articles and the second row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface is optional;
- (l) moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the second row of first articles to move in the lateral direction toward the first row of first articles in response to the first row of first articles and the second row of first articles having the first arrangement or the second arrangement, the first row of first articles and the second row of first articles forming a first partial article array, wherein in response to the first row and the second row of first articles having the third arrangement, moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the second row of first articles to move in the lateral direction toward the first row of first articles is optional;
- (m) repeating steps (g)-(l) until a first partial article array is formed including an (n−1) row of first articles;
- (n) positioning the head such that the pair of gripping members at least partially laterally surrounds an (n) row of first articles at the first location;
- (o) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (n) row of first articles;
- (p) transporting the (n) row of first articles from the first location to the second location in close proximity to the first partial article array including the (n−1) row of first articles;
- (q) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (n) row of first articles;
- (r) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface in response to the first partial article array including the (n−1) row of first articles and the (n) row of first articles having the first arrangement or the second arrangement, wherein in response to the first partial article array including the (n−1) row of first articles and the (n) row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the second support surface is optional;
- (s) moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the (n) row of first articles to move in the lateral direction toward the first partial article array including the (n−1) row of first articles in response to the first partial article array including the (n−1) row of first articles and the (n) row of first articles having the first arrangement or the second arrangement, the first partial article array including the (n−1) row of first articles and the (n) row of first articles forming a first article array,
- wherein in response to the first partial article array including the (n−1) row of first articles and the (n) row of first articles having the third arrangement, moving the head in a lateral direction parallel to the second support surface such that the other one gripping member of the pair of gripping members urging the (n) row of first articles to move in the lateral direction toward the first partial article array including the (n−1) row of first articles is optional, the first partial article array including the (n−1) row of first articles and the (n) row of first articles forming the first article array;
- (t) moving the head to a third location to pick up one of a slip sheet and a tray;
- (u) placing the one of the slip sheet and the tray over the first article array;
- (v) positioning the head such that the pair of gripping members at least partially laterally surrounds an (n+1) row of first articles at the first location;
- (w) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (n+1) row of first articles;
- (x) transporting the (n+1) row of first articles from the first location to a fourth location, the fourth location being the one of the slip sheet and the tray having a horizontal third support surface for supporting the (n+1) row of first articles and each subsequent row of first articles;
- (y) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (n+1) row of first articles;
- (z) positioning the head such that the pair of gripping members at least partially laterally surrounds an (n+2) row of first articles at the first location;
- (aa) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (n+2) row of first articles;
- (ab) transporting the (n+2) row of first articles from the first location to the fourth location in close proximity to the (n+1) row of first articles, the (n+1) row of first articles and the (n+2) row of first articles having the inputted type of arrangement of one of at least the first arrangement, the second arrangement, and the third arrangement;
- (ac) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (n+2) row of first articles;
- (ad) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the third support surface in response to the (n+1) row of first articles and the (n+2) row of first articles having the first arrangement or the second arrangement, wherein in response to the (n+1) row of first articles and the (n+2) row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the third support surface is optional;
- (ae) moving the head in a lateral direction parallel to the third support surface such that the other one gripping member of the pair of gripping members urging the (n+2) row of first articles to move in the lateral direction toward the (n+1) row of first articles in response to the (n+1) row of first articles and the (n+2) row of first articles having the first arrangement or the second arrangement, the (n+1) row of first articles and the (n+2) row of first articles forming a second partial article array,
- wherein in response to the (n+1) row and the (n+2) row of first articles having the third arrangement, moving the head in the lateral direction parallel to the third support surface such that the other one gripping member of the pair of gripping members urging the (n+2) row of first articles to move in the lateral direction toward the (n+1) row of first articles is optional;
- (af) repeating steps (z)-(ae) until a second partial article array is formed including a (2n−1) row of first articles;
- (ag) positioning the head such that the pair of gripping members at least partially laterally surrounds a (2n) row of first articles at the first location;
- (ah) the pair of gripping members applying a compressive force parallel to the first support surface to opposed laterally surrounded surfaces of the (2n) row of first articles;
- (ai) transporting the (2n) row of first articles from the first location to the fourth location in close proximity to the second partial article array including the (2n−1) row of first articles;
- (aj) moving the pair of gripping members away from one another sufficiently to remove the compressive force from the (2n) row of first articles;
- (ak) moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the third support surface in response to the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles having the first arrangement or the second arrangement, wherein in response to the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles having the third arrangement, moving one gripping member of the pair of gripping members in a direction perpendicular to and away from the third support surface is optional;
- (al) moving the head in a lateral direction parallel to the third support surface such that the other one gripping member of the pair of gripping members urging the (2n) row of first articles to move in the lateral direction toward the second partial article array including the (2n−1) row of first articles in response to the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles having the first arrangement or the second arrangement, the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles forming a second article array,
- wherein in response to the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles having the third arrangement, moving the head in a lateral direction parallel to the third support surface such that the other one gripping member of the pair of gripping members urging the (2n) row of first articles to move in the lateral direction toward the second partial article array including the (2n−1) row of first articles is optional, the second partial article array including the (2n−1) row of first articles and the (2n) row of first articles forming the second article array.
- (am) moving the head to a fourth location to pick up one of a top sheet and a tray; and
- (an) placing the one of the top sheet and the tray over the second article array.
11. The method of claim 10, wherein the third location and the fourth location are the same location.
12. The method of claim 10, prior to step (e), further comprising the steps:
- positioning a pallet on the horizontal first support surface; and
- placing one of the slip sheet and the tray on the pallet.
13. The method of claim 10, subsequent to step (an), further comprising the step of placing a top frame on the second article array.
14. The method of claim 10, wherein in step (b), the controller controls the number of articles contained in the first row of first articles, and each subsequent row of first articles, at at least one of the first location having the horizontal first support surface for supporting each row of first articles, and a fifth location having a horizontal fourth support surface for supporting each row of first articles.
15. The method of claim 10, further comprising second articles at a sixth location having a fifth support surface for supporting each row of second articles, wherein rows of second articles from the sixth location are usable to form at least one of the first article array and the second article array.
16. The method of claim 15, wherein each first article having a first height, a first width, and a first length, and each second article having a second height, a second width, and a second length, wherein at least one of the second height, the second width, and the second length of the second articles being different from the first height, the first width, and the first length of the first articles.
17. The method of claim 15, wherein each first article having a first height, a first width, and a first length, and each second article having a second height, a second width, and a second length, wherein each of the second height, the second width, and the second length of the second articles being generally the same as the first height, the first width, and the first length of the first articles.
18. The method of claim 16, wherein positioning the head such that the pair of gripping members at least partially laterally surrounds a row of first articles or a row of second articles is achieved without requiring a change-out of or modification of components of the head.
Type: Application
Filed: Oct 31, 2017
Publication Date: May 2, 2019
Inventors: Peter D. YOHE (Bloomsburg, PA), Benjamin M. KUZNICKI (Bloomsburg, PA), Justin L. MOWERY (Nescopeck, PA)
Application Number: 15/798,722