AUTOMATIC CARD PACKAGING SYSTEM AND METHOD

Abstract

A robotic card packaging system and method is provided. The system and method is provided for packaging a plurality of cards within a card container. The system and method sequentially feeds card containers onto an indexing conveyor from a card container feed magazine; applies a static label to each card container with a static label applicator; accumulates a batch of cards in a card accumulator and moves the batch of cards from the card accumulator onto a card conveyor and toward the indexing conveyor and into the card container; closes the card container after moving the batch of cards into the card container; and, applies a variable label to each card container with a variable label applicator. The system and method further verifies that the static and variable data labels have been appropriately applied to the card container with label vision apparatuses. The system and method also reads unique identifiers on each card proximate the card being fed into the card accumulator for each card in the card batch, which is then represented within the variable data label.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is non-provisional patent application which claims priority from U.S. provisional patent application No. 63/743,686, filed Jan. 10, 2025, entitled “Automatic Card Packaging System,” which is incorporated herein by reference in its entirety.

DESCRIPTION

Technical Field

The present invention relates to automated packaging systems. More specifically, the

present invention concerns automated packaging systems for plastic/PVC cards having a synthetic core and laminate layers, raised or printed indicia, and featuring magnetic strips, bar codes, and;/or EMV chips, such as gift cards.

Background of the Invention

Gift cards are well known. Some such gift cards may be sold at retail locations, such as supermarkets, coffee shops, consumer electronics stores, and the like, where they may be presented for purchase as a stack of gift cards, sold individually. Such gift cards are typically activated at the retail location.

Such gift cards are typically delivered to the retail locations as a batch of gift cards in a box, such as a box holding 25 or 50 gift cards. It may be desirable to track the batch of individual gift cards in each delivered box.

Currently such gift cards are typically manually packaged at an off-site location, which packaging may involve steps of employees handling the gift cards by hand, erecting each box, inserting the cards into each erected box, manually closing each box, and manually applying a static label and variable data label to each box. This process may require several employees, with a commensurate risk of human error.

The present disclosure is provided to address these and other problems.

SUMMARY OF THE INVENTION

It is an object of the present disclosure to provide a robotic card packaging system and method for automatically loading a batch of cards, such as plastic or PVC gift cards into a card container, such as a gift card box, applying one or more desired labels to the card container, tracking the contents of the container, and closing the card container.

Specifically, the robotic card packaging system and method is provided for packaging a plurality of cards within a card container. The robotic card packaging system and method sequentially feeds card containers onto an indexing conveyor from a card container feed magazine; applies a static label to each card container with a static label applicator; accumulates a batch of cards in a card accumulator; moves the batch of cards from the card accumulator onto a card conveyor and from the card conveyor toward the indexing conveyor and into the card container positioned at and end of the card conveyor; closes the card container after moving the batch of cards into the card container; and, applies a variable label to each card container with a variable label applicator. As a part of sequentially feeding the card containers onto the indexing conveyor from the card container feed magazine, the system and method can place each card container between lugs that are attached to the indexing conveyor, and thereafter further opening each card container by inserting a die into each card container as each card container passes the die.

The system and method can accumulate the batch of cards in the card accumulator from the feed card magazine, and after a predetermined number of cards comprising the batch of cards are accumulated in the card accumulator, lower the batch of cards onto the card conveyor. When the system and method moves the batch of cards from the card conveyor toward the indexing conveyor and into the card container, the system and method can push the batch of cards with a push plate attached to a piston and motor from a first position at one end of the card conveyor to the other end of the card conveyor toward the indexing conveyor and into the card container. A card friction feeder can feed the cards from the card container feed magazine into the card accumulator. The card accumulator can include a first batch accumulator front plate, a second batch accumulator front plate, a first batch accumulator support and a second batch accumulator support. When the system and method feeds each card into the card accumulator, each card contacts the and is stopped by the first batch accumulator front plate and the second batch accumulator front plate and comes to rest on vertical top ends of the first batch accumulator support and the second batch accumulator support. The system and method can then simultaneously lower the first batch accumulator support and the second batch accumulator support, thereby lowering the batch of cards onto the card conveyor between a first batch accumulator side plate and a second batch accumulator side plate.

When the system and method closes the card container, the system and method can fold an end flap of the card container, tuck the end flap of the card container, and move the end flap of the card container into an interior of the card container to close the card container. The system and method can verify that the static label has been appropriately applied to the card container with a label vision mechanism, and also verify that the variable data label has been appropriately applied to the card container with a label vision mechanism. Prior to the system and method applying the variable label to the card container, the systema and method can read unique identifiers on each card proximate the card being fed into the card accumulator for each card in the card batch. The variable label can include a serial number, a batch number, production information, customer information, and/or destination information in relation to the cards in the card batch.

When the system and method sequentially feeds card containers onto the indexing conveyor from the card container feed magazine, the system and method can vacuum grip each card container utilize a vacuum gripper attached to a robotic arm, after each card container gravity feeds to an opening of the card container feed magazine. The system and method also places each card container on the indexing conveyer between lugs attached to the indexing conveyer utilizing the robotic arm. When the system and method places each card container on the indexing conveyer between lugs utilizing the robotic arm, the system and method can vacuum grip an unopened card container from the card container feed magazine. The system and method can also orient the unopened card container and move the unopened card container to cause one end of the unopened card container to come into contact with one of the lugs attached to the indexing conveyor, and to cause the unopened card container to become partially opened between lugs attached to the indexing conveyor

These and other objectives and advantages may become apparent from the following description taken in conjunction with the accompanying Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:

FIG. 1 is a front view of a robotic card packaging system, such as for bulk packaging of gift cards, in accordance with the present invention;

FIG. 2 is a rear view of the card packaging system of FIG. 1;

FIG. 3 is an isometric view of the card packaging system of FIG. 1;

FIG. 4 is an illustration of a feed magazine of the card packaging system of FIG. 1;

FIG. 5 is an illustration of a robotic feed and erect mechanism of the card packaging system of FIG. 1;

FIG. 6 is an illustration of a label application and machine vision mechanism of the card packaging system of FIG. 1;

FIG. 7 is an illustration of a card box alignment mechanism of the card packaging system of FIG. 1;

FIG. 8 is an illustration of a card friction feeder mechanism of the card packaging system of FIG. 1;

FIG. 9 is an illustration of a machine vision and card data verification mechanism of the card packaging system of FIG. 1;

FIG. 10 is an illustration of a card batch processing mechanism of the card packaging system of FIG. 1;

FIG. 11 is an illustration of a card box fold/tuck/close mechanism of the card packaging system of FIG. 1;

FIG. 12 is an illustration of variable data printer (VDP) label mechanism of the card packaging system of FIG. 1;

FIG. 13 is an illustration of a machine vision label data verification mechanism of the card packaging system of FIG. 1;

FIG. 14 is an illustration of a product exit mechanism of the card packaging system of FIG. 1;

FIG. 15 is an illustration of a front view of a card friction feeder, batch accumulation section, and card conveyor of the card packaging system of FIG. 1;

FIG. 16 is a further illustration of the card friction feeder, batch accumulation section, and card conveyor of FIG. 16;

FIG. 17 is a further illustration of the card friction feeder, batch accumulation section, and card conveyor of FIG. 16;

FIG. 18 is a further illustration of the card friction feeder, batch accumulation section, and card conveyor of FIG. 16;

FIG. 19 is an illustration of a left side perspective front view of the card friction feeder, batch accumulation section, and card conveyor of FIG. 16 and other aspects of the card packaging system of FIG. 1;

FIG. 20 is a further illustration of the card friction feeder, batch accumulation section, and card conveyor, and other aspects of the card packaging system of FIG. 19;

FIG. 21 a further illustration of the card friction feeder, batch accumulation section, and card conveyor, and other aspects of the card packaging system of FIG. 19; and,

FIG. 22 is a controls diagram of the card packaging system of FIG. 1.

DETAILED DESCRIPTION

While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

A card packaging system 20, in accordance with the present invention, is illustrated in FIGS. 1, 2 and 3. It is contemplated the system 20 to be used for packaging conventional CR80 gift cards, although the system may be utilized for packaging other cards, as well. In the present embodiment, the packaging system 20 may be incorporated in first, second and third modules, or cells, designated 20a, 20b, and 20c, respectively.

As discussed in greater detail below, the first module 20a may contain a robotically operated arm 22, terminating with a vacuum gripper 22a (See also FIG. 5). The robotically operated arm 22 may be a 6-axis articulated robot, such as a Fanuc LR-Mate 200iD. The first module 20a may also contain a box feed magazine 23, which may sequentially feed boxes 23a onto an indexing conveyor, discussed below. The boxes 23a may be fed from a magazine 23b of the boxes 23a (FIG. 4), to be subsequently filled with gift cards. The boxes 23b may be what are known as crash lock bottom, or auto-lock bottom, boxes. The first module 20a may still further contain a static label applicator 24. The static label applicator 24 may apply a static label to the boxes 23a, such as a label indicating the brand of the business (i.e., a Best Buy label, for a Best Buy gift card) where the particular gift card may be redeemed. A label vision mechanism 26 (FIG. 6) may be associated with the static label applicator 24 to determine whether the static label has been appropriately applied to the boxes 23a. The label vision mechanism 26 may include a camera 26a, a light 26b and a camera trigger 26c.

The second module 20b may contain a card friction feeder 28, for sequentially feeding gift cards 28a onto the conveyor, discussed below. The second module 20b may further contain a status monitor 30 for displaying various aspects of the operating system, such as machine vision images and status. The second module 20b may still further contain a fold/tuck/close mechanism 32 which may sequentially fold the end closure of each passing card-filled box 23a, tuck-in the end closure of each passing card-filled box 23a, and then close the end closure of each passing card-filled box 23a.

The third module 20c may contain a variable data printer 36 and an exit mechanism 40. The variable data printer 36 may apply a label of ‘variable’ data, such as unique identifiers of the particular ones of the gift cards 28a contained in each one of the sequential boxes 23a.

The box feed machine 23 and the magazine 23b of the boxes 23a are shown in FIG. 4. The box feed machine 23 may sequentially gravity feed individual closed boxes 23a, to be individually picked by the vacuum gripper 22a.

Referring to FIG. 5, the vacuum gripper 22a of the robotic arm 22 may sequentially pick individual ones of the boxes 23a from the box feed machine 23, and may place the sequentially picked individual boxes 23a onto an indexing conveyor 42, referenced above. Specifically the conveyor 42 may have spaced lugs 42a, between which the boxes 23a may be placed by the robotic arm 22 onto the conveyor 42.

A box alignment mechanism 44 is illustrated in FIG. 7. The box alignment mechanism 44 may be generally located in the first module 20a, after the box feed magazine 23. The box alignment mechanism 44 may include a die 44a to open the boxes 23a as they pass, and to insure proper alignment of the boxes 23b between the spaced lugs 42a of the conveyor 42.

The card friction feeder 28 is illustrated in FIG. 8. The card friction feeder 28 may sequentially feed gift cards 28a from a card magazine 49 to a batch accumulation section 50, wherein a ‘batch’ of cards may be a quantity of the gift cards 28a (not shown) to fill one of the passing gift card boxes 23a.

Referring to FIG. 9, a card data verification mechanism 54 may be disposed proximate the card friction feeder 28, verifying each of the dispensed gift cards 28a. The card data verification mechanism 54 may include a card data verification camera 54a, light 54b and camera trigger 54c.

Referring to FIG. 10, a batch pushing mechanism 60 is illustrated, which pushes batches of the gift cards 23a into passing ones of the gift card boxes 23a. The batch pushing mechanism 60 may be located underneath the card friction feeder 28.

The fold/tuck/close mechanism 32 is illustrated in FIG. 11. The fold/tuck/close mechanism 32 may have a first section 32a which folds an end flap of a passing box 23a, a second section 32b which may tuck the end flap of a passing box 23a into the box 23b, and a third section 32c which may close the box 23a.

The variable data printer 36 is illustrated in FIG. 12. The variable data printer 36 may print a label with identifying information of the specific cards 28a contained within each one of the particular passing boxes 23b. The variable data may include serial numbers, batch numbers production information, customer and destination information, and the like. The variable data printer 36 may include a tamp 36a to press each label onto a passing one of the boxes 23b.

A label data verification mechanism 62 is illustrated in FIG. 13. The label data verification mechanism 62 may be located adjacent the variable data printer 36, to insure proper printing and application of each of the variable data labels. The label data verification mechanism 62 may include a label data verification camera 62a, light 62b and camera trigger 62c.

The product exit mechanism 40 is illustrated in FIG. 14. The product exit mechanism receives the filled, stamped and verified boxes 23a of the gift cards 28a.

Referring additionally to FIGS. 15-18, at least the card friction feeder 28 and the batch accumulation section 50 of the prior figures are shown and will be further described below, among other aspects of the card packaging system 20 and method. The batch accumulation section 50 includes a card accumulator 90. The card accumulator 90 includes a first batch accumulator front plate 100, a second batch accumulator front plate 102 spaced from but adjacent to the first batch accumulator front plate 100, a first batch accumulator support 104, and a second batch accumulator support 106 facing the first batch accumulator support 104.

The card accumulator 90 accumulates the batch of cards from the feed card magazine (not shown). The card friction feeder 28 feeds the cards 28a from the card container feed magazine into the card accumulator 90. In particular, as shown in FIGS. 15 and 16, as each card 28a feeds into the card accumulator 90, each card 28a contacts and is stopped by the first batch accumulator front plate 100 and the second batch accumulator front plate 102, with the cards 29a coming to rest and stacking on vertical top ends of the first batch accumulator support 104 and the second batch accumulator support 106. The system can be configured to input and store a predetermined number of cards 28a for each batch of cards 28a. The system is also configured to determine whether the predetermined number of cards 28a has been met as the cards 28a are accumulated in the card accumulator 90 in order to determine whether a full batch of cards 28a has been accumulated in the card accumulator 90.

An additional aspect of the card accumulation step set forth above includes that as each card 28a is fed/accumulated in the card accumulator 90 on the vertical top ends of the first batch accumulator support 104 and the second batch accumulator support 106, the system and method 20 lowers the first batch accumulator support 104 and the second batch accumulator support 106 by distance that is commensurate with the thickness of each card 28a and the distance between two stacked cards 28a. In other words, as the as each card 28a is fed/accumulated in the card accumulator 90 on the vertical top ends of the first batch accumulator support 104 and the second batch accumulator support 106, each new “top” card 28a effectively stays in the same relative position as the last “top” card 28a. This lowering of the first batch accumulator support 104 and the second batch accumulator support 106 continues and repeats as each card 28a is fed/accumulated within the card accumulator 90 until all cards in the batch of cards 28a (a full batch) has been fed/accumulated in the card accumulator 90. In this process, between the feeding of the first card 28a of the full batch of cards 28a and the feeding of the last card 28a of the batch of cards 28a, the vertical top ends of the first batch accumulator support 104 and the second batch accumulator support 106 both lower a distance that is commensurate and/or approximately equal to the height of the stacked full batch of cards 28a.

Once the full batch of cards 28a has been accumulated in the card accumulator 90 as shown in FIG. 16, the system lowers the batch of cards 28a between a first batch accumulator side plate 108 and a second batch accumulator side plate 110, and onto a card conveyor 120, as shown in FIG. 17 (lowering the batch of cards 28a, but not fully lowered to the card conveyor 120). In particular, the system can be configured to simultaneously lower the first batch accumulator support 104 and the second batch accumulator support 106, thereby lowering the batch of cards 28a onto the card conveyor 120 between the first batch accumulator side plate 108 and the second batch accumulator side plate 110.

Once the batch of cards 28a are lowered onto the card conveyor 120, the batch pushing mechanism 60 moves the batch of cards 28a from one end of the card conveyor 120 to the other end of the card conveyor 120 in the direction and toward the indexing conveyor 42, and into the card container 23a. In particular, the batch pushing mechanism 60 includes a push plate 160 and a piston 164 attached to the push plate 160. The piston 164 can be connected to a motor (not shown) for moving the piston 164 and push plate 160 toward the indexing conveyor 42, and then back into the original position shown in FIGS. 15-18. As such, as shown in FIGS. 17-21, the piston 164 and the push plate 160 push the batch of cards 28a from the first position at one end of the card conveyor 120 to second position at the other end of the card conveyor 120 toward the indexing conveyor 42 and into the card container 23a located on the indexing conveyor 42 between the lugs 42a.

Referring to FIG. 22, a control diagram is shown. A control system 200 of the card packaging system and method 20 is set forth in FIG. 22. The main or overall machine control of the card packaging system and method 20 may be provided by a main controller 210, which can be a Beckhoff Industrial PC (IPC) machine controller. The main controller 210 may provide such function as Operator/User Interface for machine control as well as machine control, including safety, all inputs/outputs, servo motion control, actuators and as a master controller for other controllers, as set forth below.

Data management for the system 20 may be provided by the main controller 210, such as by an Advantech IPC, which may provide for operator/user interface for data management; load production file for real time data comparison; receive result data stream from the machine vision controller to compare against loaded production file; and connect to a customer's SQL server for data exchange.

The control system 200 can also provide control of the robotically operated arm 22 through a robotic controller 220, such as a Fanuc dedicated purpose robot control, which may control programmed robot motion profiles upon request from the main controller 210, discussed above.

The control system 200 can also provide machine vision control through a machine vision controller 230, such as a Keyence CVX machine vision controller, which may provide a user interface to setup and control all three of the systems cameras; parse images and provide results for selected vision tools (i.e., code result, and optical character recognition); and provide results to the data management control of the main controller 210, discussed above.

All of the above controllers may communicate over a deterministic high-speed industrial network 240, such as EtherCAT. A network coupler 250, such as an EtherCAT coupler can also be used to connect other parts of the control system 200 to the main controller 210 and other controllers discussed above, including at least a servo-drive 160, a variable data label applicator 270 (discussed herein above), and a static label applicator 280 (discussed herein above).

The operation and viewable components of one embodiment of the card packaging system and method 20 is shown at https://youtu.be/2eoWLv9XO1E?si=UT9x-Gb9Oy-j2AvY, which is hereby incorporated by reference in its entirety.

It will be understood that as used herein, the terms “controller,” “computer,” and/or “server” are synonymous, and refer to a microprocessor operating computer software that is configured to perform the software tasks described herein. The card packaging system 20 described previously herein, is electronically controlled, and is equipped for that purpose with electronic circuitry including the control system 200, the main controller 210, as well as the other controller ser forth above. The main controller 210 is responsible for generating the control display or user interface connected thereto, processing commands received from the user interface, displaying information to the user and communicating with main controller 210 and other controllers described above herein.

Generally, in terms of hardware architecture the controllers include a processor, memory, and one or more input and/or output (I/O) devices (or peripherals), such as the user interface that are communicatively coupled via a local interface. The local interface can be, for example, but not limited to, one or more buses or other wired or wireless connections, as is known in the art. The local interface may have additional elements, which are omitted for simplicity, such as controllers, buffers (caches), drivers, repeaters, and receivers, to enable communications. Further, the local interface may include address, control, and/or data connections to enable appropriate communications among the other computer components.

Processor/controller is a hardware device for executing software, particularly software stored in memory. Processor can be any custom made or commercially available processor, a central processing unit (CPU), an auxiliary processor among several processors associated main controller 210 and/or other controllers, a semiconductor based microprocessor (in the form of a microchip or chip set or other microprocessor, or generally any device for executing software instructions. Examples of suitable commercially available microprocessors are as follows: a PA-RISC series microprocessor from Hewlett-Packard Company, an 80x86 or Pentium series microprocessor from Intel Corporation, a PowerPC microprocessor from IBM, a Sparc microprocessor from Sun Microsystems, Inc., STMicroelectronics'STM32 family of microprocessors, or a 68xxx series microprocessor from Motorola Corporation. Processor may also represent a distributed processing architecture such as, but not limited to, SQL, Smalltalk, APL, KLisp, Snobol, Developer 200, MUMPS/Magic.

Memory can include any one or a combination of volatile memory elements (e.g., random access memory (RAM, such as DRAM, SRAM, SDRAM, etc.)) and nonvolatile memory elements (e.g., ROM, hard drive, tape, CDROM, etc.). Moreover, memory may incorporate electronic, magnetic, optical, and/or other types of storage media. Memory can have a distributed architecture where various components are situated remote from one another, but are still accessed by processor.

The software in memory may include one or more separate programs. The separate programs comprise ordered listings of executable instructions for implementing logical functions. The software in memory includes a suitable operating system (O/S). A non-exhaustive list of examples of suitable commercially available operating systems is as follows: (a) a Windows operating system available from Microsoft Corporation; (b) a Netware operating system available from Novell, Inc.; (c) a Macintosh operating system available from Apple Computer, Inc.; (d) a UNIX operating system, which is available for purchase from many vendors, such as the Hewlett-Packard Company, Sun Microsystems, Inc., and AT&T Corporation; (e) a LINUX operating system, which is freeware that is readily available on the Internet; (f) a run time Vxworks operating system from WindRiver Systems, Inc.; or (g) an appliance-based operating system, such as that implemented in handheld computers or personal digital assistants (PDAs) (e.g., PalmOS available from Palm Computing, Inc., and Windows CE available from Microsoft Corporation). Operating system essentially controls the execution of other computer programs and provides scheduling, input-output control, file and data management, memory management, and communication control and related services.

Steps and/or elements, and/or portions thereof of the present invention may be implemented using a source program, executable program (object code), script, or any other entity comprising a set of instructions to be performed. With a source program, the program needs to be translated via a compiler, assembler, interpreter, or the like, which may or may not be included within the memory, so as to operate properly in connection with the O/S. Furthermore, the software embodying the present invention can be written as (a) an object oriented programming language, which has classes of data and methods, or (b) a procedural programming language, which has routines, subroutines, and/or functions, for example but not limited to, C, C++, Pascal, Basic, Fortran, Cobol, Perl, Java, Arduino and Ada.

The I/O devices may include input devices, for example but not limited to, the label vision mechanism 26 and the card data verification mechanism 54, other input modules for PLCs, a keyboard, mouse, scanner, microphone, touch screens, interfaces such as bar code readers, stylus, laser readers, radio-frequency device readers, cameras, etc.

Furthermore, the I/O devices may also include output devices, for example but not limited to, lights and camera triggers, output modules for PLCs, a printer, bar code printers, displays, etc. Finally, the I/O devices may further include devices that communicate both inputs and outputs, for instance but not limited to, a modulator/demodulator (modem; for accessing another device, system, or network), a WiFi interface, a radio frequency (RF) or other transceiver, a telephonic interface, a bridge, and a router.

The software in the memory may further include a basic input output system (BIOS) as may be needed for certain controllers. The BIOS is a set of essential software routines that initialize and test hardware at startup, start the O/S, and support the transfer of data among the hardware devices. The BIOS is stored in ROM so that the BIOS can be executed when the controllers are activated.

When controllers are in operation, the processor is configured to execute software stored within memory, to communicate data to and from memory, and to generally control operations of controllers pursuant to the software. The present invention and the O/S, in whole or in part, but typically the latter, are read by processor, perhaps buffered within the processor, and then executed.

When the present invention is implemented in software, it should be noted that the software can be stored on any computer readable medium for use by or in connection with any computer related system or method. In the context of this document, a computer readable medium is an electronic, magnetic, optical, or other physical device or means that can contain or store a computer program for use by or in connection with a computer related system or method. The control and other operations of present invention can be embodied in any computer-readable medium for use by or in connection with an instruction execution system, apparatus, or device, such as a computer-based system, processor-containing system, or other system that can fetch the instructions from the instruction execution system, apparatus, or device and execute the instructions. In the context of this document, a “computer-readable medium” can be any means that can store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The computer readable medium can be for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a non-exhaustive list) of the computer-readable medium would include the following: an electrical connection (electronic) having one or more wires, a portable computer diskette (magnetic), a random access memory (RAM) (electronic), a read-only memory (ROM) (electronic), an erasable programmable read-only memory (EPROM, EEPROM, or Flash memory) (electronic), an optical fiber (optical), and a portable compact disc read-only memory (CDROM) (optical).

Any process descriptions or blocks in figures represented in the figures should be understood as representing modules, segments, portions of code, or electronics which include one or more executable instructions for implementing specific logical functions or steps in the process, and alternate implementations are included within the scope of the embodiments of the present invention in which functions may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those having ordinary skill in the art.

It is to be understood that this disclosure is not intended to limit the invention to any particular form described herein, but to the contrary, the invention is intended to include all modifications, alternatives and equivalents falling within the spirit and scope of the invention. As such, while the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying Claims.

Claims

1. A robotic card packaging method for packaging a plurality of cards within a card container, comprising:

sequentially feeding card containers onto an indexing conveyor from a card container feed magazine;

applying a static label to each card container with a static label applicator;

accumulating a batch of cards in a card accumulator;

placing the accumulated batch of cards onto a card conveyor;

moving the batch of cards from the card conveyor toward the indexing conveyor and into the card container positioned at and end of the card conveyor;

closing the card container after moving the batch of cards into the card container; and,

applying a variable label to each card container with a variable label applicator.

2. The method of claim 1, wherein the plurality of cards are plastic cards.

3. The method of claim 1, wherein the plurality of cards are PVC cards.

4. The method of claim 1, wherein as a part of sequentially feeding the card containers onto the indexing conveyor from the card container feed magazine, placing each card container between lugs that are attached to the indexing conveyor, and thereafter further opening each card container by inserting a die into each card container as each card container passes the die.

5. The method of claim 1 further comprising the steps of:

accumulating the batch of cards in the card accumulator from the feed card magazine; and,

after a predetermined number of cards comprising the batch of cards are accumulated in the card accumulator, lowering the batch of cards onto the card conveyor.

6. The method of claim 1, wherein the step of moving the batch of cards from the card conveyor toward the indexing conveyor and into the card container comprises pushing the batch of cards with a push plate attached to a piston and motor from a first position at one end of the card conveyor to the other end of the card conveyor toward the indexing conveyor and into the card container.

7. The method of claim 6, wherein a card friction feeder feeds the cards from the card container feed magazine into the card accumulator, wherein the card accumulator comprises a first batch accumulator front plate, a second batch accumulator front plate, a first batch accumulator support and a second batch accumulator support, and wherein each card feeds into the card accumulator, each card contacts the and is stopped by the first batch accumulator front plate and the second batch accumulator front plate and comes to rest on vertical top ends of the first batch accumulator support and the second batch accumulator support.

8. The method of claim 7 further comprising the step of simultaneously lowering the first batch accumulator support and the second batch accumulator support, thereby lowering the batch of cards onto the card conveyor between a first batch accumulator side plate and a second batch accumulator side plate.

9. The method of claim 1, wherein the step of closing the card container comprises folding an end flap of the card container, tucking the end flap of the card container, and moving the end flap of the card container into an interior of the card container to close the card container.

10. The method of claim 1 further comprising the step of:

verifying that the static label has been appropriately applied to the card container with a label vision mechanism.

11. The method of claim 1 further comprising the step of:

verifying that the variable data label has been appropriately applied to the card container with a label vision mechanism.

12. The method of claim 1, wherein each static label comprises a brand.

13. The method of claim 1 further comprising the step of:

prior to applying the variable label to the card container, reading unique identifiers on each card proximate the card being fed into the card accumulator for each card in the card batch, wherein the variable label comprises at least one of a serial number, a batch number, production information, customer information, and/or destination information in relation to the cards in the card batch.

14. The method of claim 1, wherein the step of sequentially feeding card containers onto the indexing conveyor from the card container feed magazine comprises the steps of:

vacuum gripping each card container, after each card container gravity feeds to an opening of the card container feed magazine, utilizing a vacuum gripper attached to a robotic arm; and,

placing each card container on the indexing conveyer between lugs attached to the indexing conveyer utilizing the robotic arm.

15. The method of claim 14, wherein placing each card container on the indexing conveyer between lugs utilizing the robotic arm comprises the steps of:

vacuum gripping an unopened card container from the card container feed magazine; and,

orienting the unopened card container and moving the unopened card container to cause one end of the unopened card container to come into contact with one of the lugs attached to the indexing conveyor, and to cause the unopened card container to become partially opened between lugs attached to the indexing conveyor.

16. A robotic card packaging method for packaging a plurality of cards within a card container, comprising:

sequentially feeding card containers onto an indexing conveyor from a card container feed magazine;

accumulating a batch of cards in a card accumulator, wherein the card accumulator comprises a first batch accumulator front plate, a second batch accumulator front plate, a first batch accumulator support and a second batch accumulator support, and wherein each card feeds into the card accumulator, each card contacts the and is stopped by the first batch accumulator front plate and the second batch accumulator front plate and comes to rest on vertical top ends of the first batch accumulator support and the second batch accumulator support;

lowering the first batch accumulator support and the second batch accumulator support, thereby lowering the batch of cards onto the card conveyor;

moving the batch of cards from the card conveyor toward the indexing conveyor and into the card container positioned at and end of the card conveyor; and,

closing the card container after moving the batch of cards into the card container.