CASE-HANDLING DEVICE WITH FOLDING GUIDES

Abstract

Various embodiments of the present disclosure provide a case-handling device including movable folding guides positionable relative to a case to facilitate folding the case's upper major flaps outwardly along their respective fold lines before the case's upper minor flaps are closed.

Claims

1. A case-handling device comprising: a support; spaced-apart first and second folding guides, wherein the first and second folding guides are vertically and laterally movable relative to the support; one or more actuators operably connected to the first and second folding guides and configured to vertically and laterally move the first and second folding guides; and a controller operably connected to the one or more actuators and configured to, when a case having open first and second upper major flaps and first and second upper minor flaps is between the first and second folding guides: control the one or more actuators to move the first folding guide to a position adjacent a first fold line separating an outer surface of a first major side wall of the case and the first upper major flap; and control the one or more actuators to move the second folding guide to a position adjacent a second fold line separating an outer surface of a second major side wall of the case and the second upper major flap.

2. The case-handling device of claim 1, wherein the controller is further configured to control the one or more actuators to move the first folding guide into engagement with the outer surface of the first major side wall of the case adjacent the first fold line and to move the second folding guide into engagement with the outer surface of the second major side wall of the case adjacent the second fold line.

3. The case-handling device of claim 2, wherein the first and second folding guides comprise planar first and second bracing surfaces, wherein the first and second bracing surfaces engage the outer surfaces of the first and second major side walls of the case.

4. The case-handling device of claim 1, wherein the first folding guide comprises a first elongated body and the second folding guide comprises a second elongated body.

5. The case-handling device of claim 4, wherein the first and second elongated bodies are each longer than a length of a longest case able to be processed by the case-handling device.

6. The case-handling device of claim 1, further comprising a centering assembly comprising spaced-apart first and second centering arms that are laterally movable relative to the support, wherein the one or more actuators are operably connected to the first and second centering arms and configured to laterally move the first and second centering arms.

7. The case-handling device of claim 6, wherein the first folding guide is connected to and laterally movable with the first centering arm, wherein the second folding guide is connected to and laterally movable with the second centering arm, wherein the first folding guide is vertically movable relative to the first centering arm, wherein the second folding guide is vertically movable relative to the second centering arm.

8. The case-handling device of claim 6, wherein the controller is further configured to, when the case is between the first and second folding guides, control the one or more actuators to move the first and second centering arms toward the case to engage and center the case on the support.

9. The case-handling device of claim 8, wherein the controller is further configured to control the one or more actuators to move the first folding guide into engagement with the outer surface of the first major side wall of the case adjacent the first fold line and to move the second folding guide into engagement with the outer surface of the second major side wall of the case adjacent the second fold line, wherein the first and second folding guides and the first and second centering arms are spaced apart and engage different portions of the case.

10. The case-handling device of claim 1, wherein the support comprises a conveyor.

11. A method of operating a case-handling device, the method comprising: when a case having open first and second upper major flaps and first and second upper minor flaps is between a first folding guide and a second folding guide: moving the first folding guide to a position adjacent a first fold line separating an outer surface of a first major side wall of the case and the first upper major flap, and moving the second folding guide to a position adjacent a second fold line separating an outer surface of a second major side wall of the case and the second upper major flap.

12. The method of claim 11, wherein moving the first folding guide to the position adjacent the first fold line comprises at least one of vertically and laterally moving the first folding guide, and wherein moving the second folding guide to the position adjacent the second fold line comprises at least one of vertically and laterally moving the second folding guide.

13. The method of claim 11, further comprising simultaneously moving the first folding guide to the position adjacent the first fold line and moving the second folding guide to the position adjacent the second fold line.

14. The method of claim 11, further comprising moving the first folding guide into engagement with the outer surface of the first major side wall of the case adjacent the first fold line and moving the second folding guide into engagement with the outer surface of the second major side wall of the case adjacent the second fold line.

15. The method of claim 11, further comprising causing a controller operably connected to one or more actuators to control the one or more actuators to move the first folding guide to the position adjacent the first fold line and to control the one or more actuators to move the second folding guide to the position adjacent the second fold line.

16. The method of claim 15, further comprising causing the controller to control the one or more actuators to move the first folding guide into engagement with the outer surface of the first major side wall of the case adjacent the first fold line and to move the second folding guide into engagement with the outer surface of the second major side wall of the case adjacent the second fold line.

17. The method of claim 11, further comprising moving the first folding guide to the position adjacent the first fold line and moving the second folding guide to the position adjacent the second fold line independent of any movement of a centering assembly of the case-handling device.

18. The method of claim 11, further comprising moving the first folding guide to the position adjacent the first fold line and moving the second folding guide to the position adjacent the second fold line simultaneously with movement of centering arms of a centering assembly of the case-handling device.

19. The method of operating a case-handling device of claim 11, further comprising holding the case stationary when moving the first folding guide to the position adjacent the first fold line and when moving the second folding guide to the position adjacent the second fold line.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0013] FIG. 1A is a top perspective view of a prior art case having open upper major and minor flaps and closed lower major and minor flaps.

[0014] FIG. 1B is a top perspective view of the case of FIG. 1A with one of the upper major flaps folded outwardly above its fold line.

[0015] FIG. 1C is a top perspective view of the case of FIG. 1A with one of the upper major flaps folded outwardly below its fold line.

[0016] FIG. 2 is a perspective view of an example case-handling device of the present disclosure including two example folding guides of the present disclosure.

[0017] FIG. 3 is a side view of the case-handling device of FIG. 2.

[0018] FIG. 4 is a block diagram showing certain components of the case-handling device of FIG. 2.

[0019] FIG. 5 is a top perspective view of the case of FIG. 1A and the folding guides of the case-handling device of FIG. 2 engaging the outer surfaces of the major side walls of the case slightly below the respective fold lines of the upper major flaps.

[0020] FIG. 6 is a cross-sectional view of the case and the two folding guides of FIG. 5 taken along line A-A′ with the upper major flaps upright.

[0021] FIG. 7 is a cross-sectional view similar to FIG. 6 but with the upper major flaps folded outwardly.

[0022] FIG. 8 is a cross-sectional similar to FIG. 6 but with the upper major flaps folded inwardly.

DETAILED DESCRIPTION

[0023] While the systems, devices, and methods described herein may be embodied in various forms, the drawings show, and the specification describes certain exemplary and non-limiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connection of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as coupled, mounted, connected, etc., are not intended to be limited to direct mounting methods, but should be interpreted broadly to include indirect and operably coupled, mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

[0024] Various embodiments of the present disclosure provide a case-handling device including a folding-guide assembly including folding guides shaped, sized, and positionable to relative to a case to facilitate folding the case's upper major flaps outwardly along their respective fold lines before the case's upper minor flaps are closed.

[0025] FIGS. 2-8 show one example embodiment of a case-handling system 20 of the present disclosure and components thereof. The case-handling system 20 includes: an infeed conveyor 40, a central conveyor 60, an outfeed conveyor 80, a combined flap closer and case sealer 300, a centering assembly 400, a folding-guide assembly 500, a controller 600, and multiple sensors S.

[0026] The conveyors 40, 60, and 80 cooperate to move cases into, through, and out of the case-handling system 20. The infeed conveyor 40 is positioned upstream of the flap closer and case sealer 300, the outfeed conveyor 80 is positioned downstream of the flap closer and case sealer 300, and the central conveyor 60 is between the infeed and outfeed conveyors and below the flap closer and case sealer 300. The infeed and outfeed conveyors 40 and 80 each include a multiple rollers 42 and 82, respectively, that support the cases. The central conveyor 60 includes multiple parallel belts 62 and 64 that support the cases. The rollers 42 and 82 and the belts 62 and 64 are driven in tandem or independently by one or more drive assemblies (not shown) operated under the control of the controller 600.

[0027] The conveyor 40 is operable to deliver each case to a case-centering/flap-opening position adjacent the centering assembly 400 and the folding-guide assembly 500. After the upper major flaps of the case have been opened, the conveyor 40 is operable to move the case from that position to the conveyor 60. The conveyor 60 moves the case below and through the flap closer and case sealer 300 and delivers the case to the outfeed conveyor 80, at which point the flaps of the case have been closed and sealed. The conveyor 80 moves the case away from the case-handling system 20.

[0028] The centering assembly 400 is positioned upstream of the flap closer and case sealer 300 and along the infeed conveyor 40 and is operable to center cases on the infeed conveyor 40. The centering assembly 400 includes first and second centering arms 420a and 420b and a centering-arm actuator (not shown). The centering arms 420a and 420b are positioned on opposite sides of the infeed conveyor 40, extend generally parallel to a direction of travel of cases through the case-handling system 20 sealer 10, and are movable laterally inward (relative to the direction of travel) to laterally center the case on the infeed conveyor 40. The centering-arm actuator is operably connected to the first and second centering arms 420a and 420b (either directly or via suitable linkages) to move the centering arms between: (1) a rest configuration (FIG. 6) in which the centering arms are positioned at or near the lateral extents of the infeed conveyor 40 to enable a case to-be-sealed to be conveyed between centering arms; and (2) a centering configuration (not shown) in which the centering arms (after being moved toward one another) contact the case and center the case on the infeed conveyor 40. The controller 600 is operably connected to the centering-arm actuator to control the centering-arm actuator to move the centering arms 420a and 420b between the rest and centering configurations. The centering-arm actuator may be any suitable type of actuator, such as a motor or a pneumatic cylinder fed with pressurized gas and controlled by one or more valves.

[0029] The folding-guide assembly 500 is positioned upstream of the flap closer and case sealer 300, along the infeed conveyor 40, and adjacent the centering assembly 400 and is operable to facilitate folding the case's upper major flaps outwardly along their respective fold lines before the case's upper minor flaps are closed. The folding-guide assembly 500 includes: first and second folding guides 510a and 510, supports 512a and 514a connected to the first folding guide 510a, supports 512b and 514b connected to the second folding guide 510b, and one or more folding-guide actuators (not shown).

[0030] As best shown in FIGS. 5-8, the first folding guide 510a includes an elongated body having a lower surface 512a, an outer side surface 514a, a bracing surface 516a; and an upper surface 518a. Similarly, second first folding guide 510b includes an elongated body having a lower surface 512b, an outer side surface 514b, a bracing surface 516b; and an upper surface 518b. In this example embodiment, the upper surfaces 518a and 518b are curved while the other surfaces are planar. The folding guides 510a and 510b may have any suitable length, size, and shape. In various embodiments, the length of each folding guide may be shorter than, longer than, or the same length as the longest case that can be closed and sealed by the case-handling device 20.

[0031] In this example embodiment, the supports 512a and 514a are connected to the first centering arm 420a, and the supports 512b and 514b are connected to the second centering arm 420b. This results in the folding guides 510a and 510b extending generally parallel to a direction of travel of cases through the case-handling system 20 and above the centering arms 420a and 420b, respectively. The folding guides 510a and 510b are also movable laterally inward and outward (relative to the direction of travel) with the centering arms 420a and 420b as the centering arms move between their rest and centering configurations. The folding-guide actuators are operably connected to the first and second folding guides 510a and 510b (via the supports) to move the folding guides upward and downward relative to the centering arms 420a and 420b, the infeed conveyor 40, and the cases. The folding-guide actuators may be any suitable type of actuator, such as motors or pneumatic cylinders fed with pressurized gas and controlled by one or more valves. The controller 600 is operably connected to the folding-guide actuators to control the folding-guide actuators to move the folding guides. Accordingly, in this example embodiment, the folding guides 510a and 510b are movable relative to cases laterally inward and outward and upward and downward under the control of one or more actuators. In this example embodiment, the folding guides 510a and 510b are coupled or otherwise configured such that they simultaneously move vertically and laterally, though in other embodiments they are not coupled as such.

[0032] As described in more detail below, in operation, the controller 600 controls the appropriate actuators to move the folding guides 510a and 510b relative to a case C such that, as best shown in FIGS. 6-8, their respective bracing surfaces 516a and 516b engage (or in other embodiments, are slightly spaced-apart from) the respective outer surfaces of the major side walls SW1 and SW2 of the case C at or slightly below the upper fold lines F5 and F7. The combination of the elongated shape of the folding guides, their vertical position at or slightly below the fold lines, and their engagement with (or slight offset from) the major side walls results in the upper major flaps UMa1 and UMa2 folding outwardly (to make room for the upper minor flaps as shown in FIG. 7) or inwardly (after the minor flaps have been closed and as shown in FIG. 8) along their respective fold lines. Accordingly, in this example embodiment, the case C is braced from the side via engagement of the centering arms near the bottom of the major side walls and via engagement of the bracing surfaces of the folding guides near the top of the major side walls.

[0033] In other embodiments, the folding guides are not attached to and are vertically and laterally movable independently of the centering arms of the centering assembly. In these embodiments, the folding-guide actuators are operably connected to the first and second folding guides (via the supports) to move the folding guides upward and downward and laterally inward and outward relative to the centering arms, the infeed conveyor, and the cases, and the controller is operably connected to the folding-guide actuators to control the folding-guide actuators to move the folding guides.

[0034] In other embodiments, the shapes of one or more of the folding guide can vary such as, but not limited to being round, square, or triangular. In other embodiments, one or more of the folding guides include multiple connected or separate sections. In other embodiments, one or more of the folding guides can include one or more relatively small rollers or bearings.

[0035] The combined flap closer and case sealer 300 is operable to close the upper minor flaps of a case, then close the upper major flaps of the case, and then apply tape to the closed upper and lower major flaps. The combined flap closer and case sealer 300 includes a carriage 310 supported by and vertically movable relative to spaced-apart supports 312 and 314. The carriage 310 includes slide plates 322 and 324, a crossbar 330 attached to and extending between the slide plates 322 and 324, and an elongated support 340 attached to the crossbar 330. The slide plates 322 and 324 are slidably mounted to the supports 312 and 314. A carriage actuator (not shown) is operably connected to the carriage 310 and configured to move the carriage 310 vertically to adapt to cases of different heights. The controller 600 is operably connected to and configured to control the carriage actuator.

[0036] The support member 340 supports a stationary leading minor flap closer 342, a movable trailing minor flap closer 344, a first major flap closer 346, and a second major flap closer (not shown). More specifically, the stationary leading minor flap closer 342 extends downward from an underside of the support 340 and positioned, shaped, oriented, and otherwise is configured to engage the leading surface of the first upper minor flap UMi1 of a case C as central conveyor 60 moves the case C into contact with the stationary leading minor flap closer 342. Continued movement of the case C past the stationary leading minor flap closer 342 results in the first upper minor flap Until closing. The movable trailing minor flap closer 344 pivotably attached to the support 340 and configured to pivot downwardly (via a minor-flap-closer actuator (not shown) controlled by the controller 600) to engage and close the second upper minor flap UMi2 of the case C as the case moves under the combined flap closer and case sealer 300. The first and second major flap closers are positioned on opposite sides of the leading minor flap closer 342 and are positioned, shaped, oriented, and otherwise configured to engage and close the upper major flaps UMa1 and UMa2 of the case C as the central conveyor 60 moves the case C into contact with and past the major flap closers.

[0037] The flap closer and case sealer 300 also includes a tape applicator 380 that includes a tape cartridge 381 (partially shown) supporting a roll of tape 390. The tape applicator 380 is configured to apply tape from the roll 390 to the closed upper major flaps UMa1 and UMa2 and minor side walls of the case as the central conveyor 60 moves the case C beneath and past the tape cartridge 381.

[0038] The controller 600 controls, communicates with, and operates with the components of the case-handling device 20, including various actuators, drive assemblies, and sensors referenced above. The controller 600 is configured to control movement or operation of at least part of the conveyors, the combined flap closer and case sealer 300, the centering assembly 400, and the folding-guide assembly 500. The controller 600 can be any suitable type of controller (such as a programmable logic controller) that includes any suitable processing device(s) (such as a microprocessor, a microcontroller-based platform, an integrated circuit, or an application-specific integrated circuit) and any suitable memory device(s) (such as random-access memory, read-only memory, or flash memory). The memory device(s) stores instructions executable by the processing device(s) to control operation of the case-handling device 20.

[0039] In operation, the controller 600 controls the infeed conveyor 40 to move a case C toward the flap closer and case sealer 300. When the case C is between the centering arms 420a and 420b of the centering assembly 400 and between the folding guides 510a and 510b of the folding-guide assembly 500, one of the sensors S (such as a photocell) is triggered. This causes the controller 600 to: stop the infeed conveyor 40, move the centering arms 420a and 420b laterally inwardly to center the case C on the infeed conveyor 40, and move the folding guides 510a and 510b until their respective bracing surfaces 516a and 516b engage (or in other embodiments, are slightly spaced-apart from) the respective outer surfaces of the major side walls SW1 and SW2 of the case C at or slightly below the upper fold lines F5 and F7. In other embodiments, the controller 600 does not stop the movement of the case, and in such embodiments, the controller can change speed of the movement of the case or cause the movement of the case to remain constant. After another component of the case-handling system 20 or an operator folds the upper major flaps UMa1 and UMa2 of the case C outwardly, the case C is moved onto the central conveyor 60. The central conveyor 60 moves the case C beneath the flap closer and case sealer 300, which closes the upper minor and major flaps and tapes them shut, as explained above.

[0040] The controller 600 determines the proper position of the folding guides based on the size of the case (e.g., its height and width). In certain embodiments, one or more of the sensors S detect the height, width, and/or other measurements of the case upstream of the folding-guide assembly, and the controller determines where to position the folding guides based on those measurements. In other embodiments, the controller receives the measurements from another component in the packaging line. In further embodiments, the controller receives instructions as to where to position the folding guides from another component in the packaging line.

[0041] The present disclosure thus provides methods for sealing cases of different sizes using a single case-handling device that includes a side wall securing method that better ensures that the upper major flaps will be bent along the upper fold lines for those upper major flaps. In various embodiments, the side wall securing method includes: (a) positioning the case at a flap opening position; and (b) moving folding guides inwardly to engage opposite outer side surfaces of the case slightly below the respective major fold lines for the case to brace such sides of the case, such that the upper major flaps will be more likely to be opened along the respective fold lines for those upper major flaps. In various embodiments, the method further includes moving the folding guides upwardly or downwardly such that the engagement of the opposite outer side surfaces of the case is slightly below the respective major fold lines for the case. The method thus better ensures that the upper major flaps of the case are folded outwardly along the respective fold lines of the case before the upper minor flaps of the case are closed, and better ensures that the upper major flaps of the case can be subsequently folded inwardly along the respective fold lines.