Patent Application
20240246721
This invention relates generally to methods and systems for forming pallets and in particular to methods and systems for forming corrugated pallets.
Pallets are commonly used to handle loads of material such that they can be stored, stacked and transported. A typical pallet includes a flat surface for supporting the load having parallel elongate runners secured to the underside. The runners provide strength to the pallet to support the load whilst the spacing of the runners permits the forks of equipment such as a front-end loader or forklift truck to be inserted in between the runners such that the pallet and its supported load may be lifted and moved.
Pallets currently in use may be capable of supporting loads of up to 3000 kg and currently, many pallets are commonly manufactured from wood secured together by nails or other fasteners. Whilst relatively cheap to produce, the use of wood in the manufacture of pallets has several drawbacks. Firstly, the nails or other fasters used to secure the pallet together may cause damage to the supported load and present a hazard to people handling the pallets. Whilst strong, wooden pallets are heavy, which adds to the cost of transportation. This may especially be problematic as once used, they are not easily recycled on site and must be transported to a recycling facility or landfill. In some jurisdictions landfill disposal may be economically unviable due to increasing disposal fees, limiting disposal limits to very low percentages or even unavailable due to being banned completely. Additionally, when transporting goods internationally, wooden pallets may require additional inspections or even a quarantine period due to ecological concerns arising from the potential of the wood to harbor non-native insects or other biological hazards.
As an alternative to wooden pallets, paperboard sheets and/or corrugated cardboard may be used to produce a corrugated pallet. In a corrugated pallet, a corrugated top deck is supported by a combination of parallel runners or support block constructed from a paper material such as for example a honeycomb block or compressed cardboard material. Corrugated pallets may be up to 75% lighter than wooden pallets and may be produced from recyclable material whilst being recyclable themselves. However, especially in comparison to wooden pallets, existing designs of corrugated pallets require complex and expensive equipment to manufacture and operate at slow production rates. In many known systems, formation of the runners commonly involves a complex sequence where more than one feedstock is combined in a multi-step sequence. Therefore, it remains challenging to economically produce a sufficiently strong and durable corrugated pallet.
Accordingly, it is desirable to provide improved pallets and pallet runners, and methods and apparatuses for forming the same.
An embodiment as disclosed herein relates to an elongate pallet runner comprising a plurality of panels, each panel bent relative to an adjacent panel to form a continuous spiral structure having a cross-sectional profile that is nested, each panel having a planar surface that abuts against a planar surface of another panel.
In some embodiments, the cross-sectional profile comprises nested layers of bent panels, each nested layer having a same geometric shape.
In some embodiments, each panel is orientated perpendicular to its adjacent panel.
In some embodiments, each panel is separated from its adjacent panel by a respective fold line. In some embodiments, each panel is folded relative to its adjacent panel about the respective fold line.
In some embodiments, at least some of the abutting panels are adhered to each other by an adhesive.
In some embodiments, the plurality of adjacent panels are integrally formed.
In some embodiments, the elongate pallet runner has a rectangular cross-sectional profile.
In some embodiments, the elongate pallet runner is formed of corrugated cardboard.
In some embodiments, an innermost panel of the spiral structure includes a diagonal portion that does not abut against the planar surface of another panel.
Another embodiment as disclosed herein relates to a pallet comprising a deck having a top side and a bottom side and a plurality of elongate pallet runners secured to the bottom side of the deck. Each of the plurality of elongate pallet runners comprises a plurality of panels, each panel bent relative to an adjacent panel to form a continuous spiral structure having a cross-sectional profile that is nested, each panel having a planar surface that abuts against a planar surface of another panel.
In some embodiments, the cross-sectional profile comprises nested layers of bent panels, each nested layer having a same geometric shape.
In some embodiments, each panel is orientated perpendicular to its adjacent panel.
In some embodiments, each panel is separated from its adjacent panel by a respective fold line. In some embodiments, each panel is folded relative to its adjacent panel about the respective fold line.
In some embodiments, at least some of the abutting panels are adhered to each other by an adhesive.
In some embodiments, the plurality of adjacent panels are integrally formed.
In some embodiments, each elongate pallet runner has a rectangular cross-sectional profile.
In some embodiments, each elongate pallet runner is formed of corrugated cardboard.
In some embodiments, the pallet comprises three elongate pallet runners.
In some embodiments, the deck and plurality of elongate pallet runners are made from corrugated cardboard.
In some embodiments, the deck is a first deck and wherein the corrugated pallet further comprises a second deck having a top side and bottom side, wherein the plurality of elongate pallet runners are secured to the top side of the second deck.
Another embodiment as disclosed herein relates to a method of forming a corrugated pallet. The method comprises affixing a plurality of elongate pallet runners to the same side of a deck. Each of the plurality of elongate pallet runners comprises a plurality of panels, each panel bent relative to an adjacent panel to form a continuous spiral structure having a cross-sectional profile that is nested, each panel having a planar surface that abuts against a planar surface of another panel.
In drawings which illustrate embodiments of the invention,
With reference to
Runner blank 100 may be cut from a single sheet of corrugated material or other sheet material and may be divided into a series of adjacent elongate rectangular panels A-X, which may be transverse, and which may be integrally formed and/or fixedly connected with adjacent panels. Runner blank 100 may be made from an assortment of foldable materials, including cardboard, paperboard, plastic materials, composite materials, or the like and possibly even combinations thereof.
As shown in
During formation of a pallet runner, fold lines 102-146 (shown in solid lines in
With reference to
At step 100(3), the leading edge of panel A, i.e., the first vertical (outer) edge of panel A may be engaged by a panel rotating apparatus and is rotated in a clockwise direction such that panel A is pivoted relative to panel B. Between steps 100(3) and 100(4), continued engagement and rotation of panel A by the panel rotating apparatus in a clockwise direction occurs and continues between steps 100(3) and 100(5) to form a pallet runner 150.
Runner 150 is depicted in greater detail in
As will be understood, in order to form the spiral cross-sectional profile of runner 150, the width of panels that are parallel to each other in pallet runner 150 (such as panels A, E, I, M, Q, U, panels B, F, J, N, R, V, panels C, G, K, O, S, W and panels D, H, L, P, T, X) must increase in size in an outwards direction from the centre of runner 150 in order the accommodate the increasing sizer of runner 150. The progression of the increase in width between adjacent parallel panels in an outwards direction as viewed in
For example, as can be seen in
It will be appreciated that the thickness (or flute size) of blank 100 will have an effect on the height and width of the completed runner. Generally speaking, as the thickness of blank 100 increases, the height and width of runner 150 will also increase, providing that the panel widths remains the same. In an embodiment, runner 150 may have a height of between about 3 inches and about 4.5 inches and may preferably have a height of about 3.75 inches.
In the embodiment shown in
With particular reference to
Runners 150a, 150b, 150c may be secured to deck 170 by any suitable method, such as by a layer of adhesive or a mechanical fastener such as staples, clips or screws. Deck 170 may be any suitable shape, such the square configuration shown in
With reference to
As shown in
Pallet formation subsystem 206 may include a frame 214 and may utilize one or more engagement heads configured to engage and move components such as blank 100, runner 150, deck 170 or pallets 160. Pallet formation subsystem 206 may include first engagement head 216a for retrieving a runner blank 100 from runner blank conveyor 202 and moving blank 100 to runner forming station 210, a second engagement head 216b for retrieving a formed runner 150 from runner forming station 210 and moving runner 150 to pallet assembly station 212 and third engagement head 216c for retrieving corrugated pallets 160 from pallet assembly station 212 and moving to takeaway conveyor 208.
Engagement heads 216a-c may be any suitable apparatus configured to releasably engage a component (e.g., runner blank 100, runner 150, deck 170 or corrugated pallet 160) of system 100 and may each be moved by a movement subsystem, which may include one or more movement apparatuses. For example, first engagement head 216a may be mounted to and moved by a first movement apparatus 218a. Second engagement head 216b may be mounted to and moved by a second movement apparatus 218b. Third engagement head 216c may be mounted to and moved by a third movement apparatus 218c. Movement apparatuses 218a-c may be any suitable apparatus configured to move their respective engagement head in one or more directions.
An example of a scheme for the power and data/communication configuration for pallet forming system 200 is illustrated in
Electrical power can be supplied to PLC 500/HMI 510, and to all the various servo motors and DC motors that are described further herein. Compressed/pressurized air can also be supplied to the vacuum generators through valve devices such as solenoid valves that are controlled by PLC 500, all as described further herein. Servo motors may be connected to and in communication with servo drives that are in communication with and controlled by PLC 500. Similarly, DC motors may be connected to DC motor drives that are in communication with and controlled by PLC 500; again all as described further herein. Additionally, various other sensors are in communication with PLC 500 and may (although not shown) also be supplied with electrical power.
Runner blank conveyor 202 is shown in isolation in
The stack of runner blanks 100 may be loaded onto runner blank conveyor 202 at a first position 236. The stack of runner blanks 100 may be conveniently loaded onto conveyor 202 on pallet 242, such as by a fork lift truck. In other embodiments, blanks 100 may be placed directly onto conveyor 202. The stack of runner blanks 100 may be advanced in direction 234 to a second (or pickup) position 238, where a blank 100 may be engaged by first engagement head 216a of pallet formation subsystem 206 and moved by first movement apparatus 218a to runner forming station 210. Once all blanks 100 of the stack of runner blanks 100 have been moved from second position 238, the remaining pallet 242 may be moved to third position 240 and stacked by pallet stacking apparatus 244, which is configured to stack empty pallets 242 into vertical stacks for removal.
A conveyor belt (not shown) may be provided that may be driven by a suitable motor such as a DC motor or a variable frequency drive motor 228a. The motor may be DC motor and may be controlled through a DC motor drive (all sold by Oriental™ under model AXH-5100-KC-30) by PLC 500 (
The presence of a stack of blanks 100 at the pickup position 238 may be detected by a sensor 540 (
The presence of a stack of blanks at the second or pick up location 238 may be detected by sensor 540. The sensor may send a digital signal to PLC 500 signalling a stack of blanks are at the pick-up position. Referring back to
First engagement head 216a is shown in greater detail in
In other embodiments arms 248a-e may be permanently affixed to or formed as an integral part of member 246.
At the distal end of each of arms 248a-e may be one or more suction cups 254 (not shown in
A solenoid valve device 530 (
In other embodiments, a vacuum pump mounted externally may generate vacuum externally and then vacuum can be supplied through the aforementioned air channels.
Returning to
In other embodiments, first movement apparatus 218a may be configured with any suitable number and configurations of arms similar to arms 248a-e as required to engage a blank.
First engagement head 216a and first movement apparatus 218a are shown in isolation in
First movement apparatus 218a includes a vertically orientated support tube 256a that may be generally rectangular in cross section to which first engagement head 216a is mounted by mounting brackets 258 (
Support tube 256a is slidably mounted to a pair of slide blocks 260, 262, each mounted on opposing sides of support tube 256a (
Support tube 256a has a generally vertically orientated rail system to allow support tube 256a to be connected slide blocks 260, 262 such that support tube 256a may move vertically relative to slide blocks 260, 262. More specifically, rails 275, 277 extend vertically along opposed sides of tube 256a. Rail 275 is secured to slide block 262 by inner blocks 279a, 279b (
In order to drive first movement apparatus 218a horizontally (in the X-direction in
Four freely rotatable pulley wheels 280a, 280b, 280c and 280d are secured between the inner vertical faces of slide blocks 260, 262 and a further freely rotatable pulley wheel 280e is attached to the upper end of support tube 256a.
One end of a drive belt 282, which may for example be made from urethane with steel wires running through it is fixedly attached to the bottom of support tube 256a by a belt block 284a (
With this arrangement, by adjusting the relative rotations of drive wheels 276 and 278 through the operation of motors 272a and 274a, the vertical position of support tube 256a relative to slide blocks 260 and 262 can be adjusted. Additionally, by adjusting the relative rotations of drive wheels 276 and 278, the horizontal position of slide blocks 260 and 262 on rails 264, 266 can be adjusted thus altering the horizontal position of support tube 256a and first engagement head 216a. It will thus be appreciated that by adjusting the direction and speeds of rotation of drive wheels 276 and 278 relative to each other the support tube 256a can be moved vertically and/or horizontally in space within the physical constraints imposed by among other things the position of the drive wheels 276 and 278, the length of the belt 282, and the length of support tube 256a. The following will be appreciated in particular:
In some embodiments, first movement apparatus 218a may also be configured such that first engagement head 216a may also move in the Y-direction (i.e., directions parallel to the Y axis in
As described above, at either end rails 264, 266 may be affixed to and supported by support plates 268, 270 (
Servo motor 286a may be mounted to a gearbox 296 which is in turn interconnected to longitudinally extending driveshaft 298 such that driveshaft 298 can be driven in both directions at varying speeds by PLC 500. The opposed ends of drive shaft 298 are connected to pulleys 300a, 300b, which each drive continuous belts 302a, 302b.
Belt 302a may extend in a transverse direction from the lower side of pulley 300a, generally following rail 288 to the lower side of a pulley 304a, mounted above the opposite end of rail 288 to pulley 300a. From there belt 302a extends to the upper side of pulley 304a and in a transverse direction to the upper side of pulley 300a. Belt 302a is also connected to support plate 268, such movement of belt 302a will drive movement of support plate 268 along rail 288.
Similarly, belt 302b may extend in a transverse direction from the lower side of pulley 300b, generally following rail 290 to the lower side of a pulley 304b, mounted above the opposite end of rail 290 to pulley 300b. From there belt 302b extends to the upper side of pulley 304b and in a transverse direction to the upper side of pulley 300b. Belt 302b is also connected to support plate 268, such movement of belt 302b will drive movement of support plate 270 along rail 290.
With this arrangement, through operation of servo motor 286a the horizontal position in the Y-direction of support plates 268, 270 and thus rails 264, 266, support tube 256a and first engagement apparatus 216a can be adjusted relative to rails 288, 290. Movement in the Y direction may be desirable for example, in order to facilitate changeovers of components of pallet forming system 200 (such as components of first engagement head 216a) to allow access to components of system 200, to align blank 100 correctly in the Y-direction on conveyor 220 or to transfer a blank to/from another location. This may be especially beneficial when using different sized blanks with system 200, such that first engagement apparatus 216a can successfully engage and transfer the blank to the correct position on conveyor 220.
The following will be appreciated in particular:
It will be appreciated that if the speeds and directions of the motors 272a, 274a, 278 are varied in different manner, then the motion of the support tube 256a (and thus first engagement head 216a) can be created that has both a vertical component as well as a horizontal component. Thus, any desired path within these three degrees of freedom (vertical in the Z direction and horizontal in the X and Y directions) can be created for support tube 256a—and thus for first engagement head 216a (such as a path having curved portions). Thus, by controlling the rotational direction and speed of the motors 272a, 274a, 278 independently of each other, PLC 500 can cause support tube 256a (and thus first engagement head 216a) to move along any path within these two degrees of freedom, within the physical constraints imposed by the spacing of the wheels 276, 278 in the X direction, the spacing of pulley wheel 280e, and the bottom of support tube 256a in the Z direction and the spacing between pulleys 300a, 300b and pulleys 304a, 304b in the Y direction.
An encoder may be provided for each of the servo drive motors 272a, 274a and the encoders may rotate in relation to the rotation of the respective drive wheels 276, 278. The encoders may be in communication with, and provide signals through the servo drives to PLC 500. Thus PLC 500 can in real time know/determine/monitor the position of the belt 282 in space and thus will determine and know the position of the first engagement head 216a in space at any given time.
Similarly, an encoder may be provided for servo drive motor 286 which rotates in relation to the rotation of driveshaft 298. The encoder may be similar to the encoders described above may be in communication with, and provide signals through the servo drives to PLC 500. Thus PLC 500 can in real time know/determine/monitor the belts 302a, 302b in space and thus will determine and know the position of the first engagement head 216a in the Y direction.
The particular types of encoders that may be used are known as “absolute” encoders. Thus the system can be zeroed such that due to the calibration of both encoders of both servo drive motors 272a, 274a, 286a the zero-zero position of the end effector in both X, Y and Z directions is set within PLC 500. The zero-zero position can be set with the end effector at its most horizontally left (in the X direction), most horizontally back (i.e., furthest in the Y2 direction) and vertically raised position. PLC 500 can then substantially in real time, keep track of the position of the end effector 500 as it moves through the processing sequence for a blank 100.
Also associated with first movement apparatus 218a is a first, generally horizontally oriented caterpillar device 310 and a second generally vertically oriented caterpillar device 312 (
Also associated with first movement apparatus 218a are third and fourth, generally horizontally orientated caterpillar devices 314a, 314b (
The caterpillars allow hoses and wires to supply first engagement head 216a. In this way both pressurized air/vacuum and/or electrical communication wires may be brought from locations external to the frame 214 onto the moving first engagement head 216a. An example of suitable caterpillar devices that could be employed is the E-Chain Cable Carrier System model #240-03-055-0 made by Igus Inc. It should be noted that electrical communication between the PLC 500 and the first engagement head 216a could in other embodiments be accomplished using wireless technologies that are commercially available.
Through operation of first movement apparatus 218a as described above, first engagement head 216a may be moved towards a stack of blanks at second (or pick up) position 238 on runner blank conveyor 202 (
Runner forming station 210 is depicted in isolation in
Conveyor 220 may have a continuous belt 316 which may be supported for longitudinal movement at opposite ends by a drive pulley and an idle wheels (not shown in FIGS.). The drive pulley may be connected to a drive motor 317 (
Belt 316 may include a first engagement feature, such as first outwardly projecting ridge 318a configured to engage an edge 100a of a blank 100 that is placed on conveyor 220 by first movement apparatus 218a, as depicted schematically in
With reference to
With reference to
Scoring roller 222 may be any suitable scoring apparatus operable to form one more fold lines on blank 100. The fold lines may comprise a weakened area of material, such a crease, a score line or a series of spaced apart perforations in blank 100. The weakened area of material may allow blank 100 to be folded about each fold line, as will be described in more detail below. In the embodiment shown in
In some embodiments, the fold lines may not be continuous. For example, one of more of the fold lines may be intermittent/stippled across blank 100. Further, the fold lines may not extend transversely entirely along blank 100. The aforementioned fold line configurations may be dictated by the shape and length of protrusions 322 of scoring roller 222.
Whilst the embodiment shown in the FIGS. illustrates a scoring roller, the scoring apparatus may be any suitable apparatus configured to form one or more fold lines as described above on blank 100. For example, the scoring apparatus may comprise a mechanical press or cutting apparatus configured to move vertically (in the z-direction) at a particular frequency (or changing frequency) to apply a desired pattern of creases, score lines or perforations at a desired spacing on blank 100. In an embodiment, the scoring apparatus comprises a steel rule die.
At one end of drum 320, scoring roller 222 may be connected to a servo motor 324 through a gearbox 326 such that scoring roller 222 is configured for rotational movement about a generally horizontal axis of rotation 327 (parallel to the Y-axis on
As blank 100 is advanced in direction 229 one of the protrusions 322 on scoring roller 222 may engage a portion of the upper surface of blank 100 to form a fold line across the width of blank 100 (generally parallel to the Y-axis in
The depth of the crease or score lines formed in blank 100 may be affected by the distance between scoring roller 222 and conveyor 220 and the thickness of blank 100. The profile of the tip at the distal end of each of the protrusions may also affect the crease or score line formed in blank 100. Generally speaking, a wider tip at distal end of each of the protrusions 322 may favour forming a crease in blank 100 rather than a score line. Conversely a narrower tip at distal end of each of the protrusions 322 may favour forming a score line in blank 100 rather than a crease.
Throughout steps 1000(2) and 1000(8), as blank 100 is further advanced in direction 229 through movement of conveyor 220, scoring roller 222 will also rotate such that protrusions 322 will continue to engage portions of the upper surface of blank 100, creating a series of fold lines may be formed on blank 100, such as fold lines 102-146, thereby dividing blank 100 into panels A-X (as shown in
The spacing of each of the adjacent fold lines formed in blank 100 may be dependent on factors such as the speed of movement of conveyor 220 (and therefore the speed of movement of blank 100 in direction 229) and speed of rotation of scoring roller 222 relative to each other. Both may be controlled by PLC 500 to create the desired spacing between adjacent fold lines. As the spacing between fold lines formed on a blank affects the dimensions of the pallet runner formed from the blank, PLC 500 may be programmed to create a desired a spacing of fold lines to form a pallet runner of desired dimensions.
Whilst not shown in the FIGS., runner forming station 210 may include one or more sensor in communication with PLC 500. In various embodiments, a sensor may monitor the position and speed of rotation of conveyor 220, the speed of rotation of scoring roller 222, the position of protrusions 322 of scoring roller 222, the position of blank 100/runner 150 on conveyor 220 and/or the position of mandrel 336. PLC 500 may make adjustments to runner forming station 210 based on the signal(s) received from one or more of these sensors.
Whilst scoring roller 222 as depicted in the FIGS. is shown with four protrusions 322, in various embodiments scoring roller 222 may have any number of projections. The number of protrusions may be beneficial in forming different numbers or different spacing of fold lines in a blank such as blank 100.
As blank 100 is further advanced in direction 229 through movement of conveyor 220 adhesive may be applied to some or all of the upper surface of blank 100 by any suitable adhesive applicator apparatus such as adhesive applicator apparatus 224. In an embodiment, adhesive may be applied to all of the upper surfaces of the panels of blank 100.
Applicator apparatus 224 is shown in greater detail in
In other embodiments, adhesive applicator apparatus may have any suitable number or arrangement of nozzles.
An example of a suitable adhesive applicator apparatus 224 that can be employed is the model ProBlue-7 hot melt application system made by Nordson™ Inc. which includes adhesive tank, nozzles/guns and hoses as well as solid state temperature control for the tank, guns and hoses.
Various types of adhesives may be employed in adhesive applicator apparatus 224. A particular class of adhesives that may be suitable are adhesives in the class of “Hot Melt Adhesives” (referred to as a “HMA”). HMAs may be a thermoplastic adhesive/glue which may be heated in an applicator such as applicators 330a-i by respective heating elements and then expelled from the applicators while hot and tacky onto surfaces which are to be adhered to other surfaces. Depending upon the particular formulation of the HMA selected, the adhesive may for example remain tacky and capable of bonding two surfaces together for, from perhaps a second or a few seconds, to up to a minute or more. In runner forming station 210, an HMA may be applied to the upper surface of certain panels of a blank 100 by applicators 330a-i, to form adhesive lines such as adhesive lines extending transversely across blank 100.
One particular type of HMAs are pressure sensitive HMAs which may remain tacky and capable to bonding two surfaces together until pressure is applied to the HMA, such as when the HMA is compressed between two surfaces of two panels of a blank 100 as the two panels are brought together. Such pressure sensitive HMAs may remain tacky and capable of bonding two surfaces together for a long period of time until pressure is applied to the HMA.
An example of a suitable adhesive that could be employed on a blank 100 made of cardboard is Cool-Lok adhesive made by Nacan™ Products Limited or a suitable pressure sensitive HMA made by Henkel™ Corporation.
In other embodiments, the adhesive applicator apparatus 224 may be pressurized cold seal glue system such as those manufactured by Nordson™ Inc.
One particular type of adhesive that may be applied to blank 100 may be a pressure sensitive adhesive or cold seal adhesive material. Such materials are known and may comprise a quick-drying, adhesive (for e.g. latex rubber, an acrylic resin, a polyurethane resin, a silicone resin, an acrylonitrile-butadiene or isoprene copolymer resin) that once dried, will create a surface with essentially no tackiness and will only adhere to other surfaces coated with the same adhesive and when placed under pressure. Such a pressure or cold seal adhesive may be capable of being applied to a substrate material at a relatively high rate of production (e.g. such as during a paperboard converting process when multiple blanks are being formed) and of drying relatively quickly. As a result, such a cold seal adhesive applied to blank 100 enables blanks 100 to be manufactured at relatively high production rates. Examples of such pressure sensitive adhesives and cold seal adhesives are discussed in Treatise on Adhesion and Adhesives Vol. 2, “Materials”, R. I. Patrick, Ed., Marcel Dekker, Inc., N.Y. (1969); Adhesion and Adhesives, Elsevier Publ. Co., Amsterdam, Netherlands (1967); Handbook of Pressure-Sensitive Adhesive Technology, Donates Satas, Ed., VanNostrand Reinhold Co., N.Y. (1982); EP 0372756 B1; and U.S. Pat. No. 8,895,656 the entire contents of which are hereby incorporated herein by reference. Suitable cold seal adhesives that may be employed are available from Henkel Corporation.
Adhesive applicators 330a-i may be individually secured and adjusted by use of releasable adjustment mechanisms 334a-i which releasably secures the applicators 330a-i to support beam 328, at positions suitable dependent upon which particular type/configuration of case blank 100 that is being processed. This adjustable positioning of adhesive applicators 330a-i is a feature of pallet forming system 200 that enables pallet forming system 200 to be easily modified when changing over from handling one type/configuration of blank to another type/configuration of blank.
In some embodiments, small portions of a HMA may be applied to a panel of blank 100 in order to tack adjacent panels in place during the subsequent folding steps and a cold seal adhesive may also be applied along the length of the panel. The HMA will initially secure the adjacent panels in place until the cold seal adhesive is dried and adhered.
In some embodiments, the adhesive applicator apparatus may be configured to selectively stamp or roll adhesive onto one or more panels of blank 100.
Referring back to
Panel rotating apparatus 226 is depicted in isolation in
Mandrel 336 includes a first portion 340 and a second portion 342, which may both be elongated structures with a generally triangular cross sectional shape. First portion 340 and second portion 342 may be or solid or tubular. First portion 340 may have a cross-sectional shape in the form of a right angle triangle, with outer facing sides 340a and 340b and an inner facing side (or hypotenuse) 340c. Similarly, second portion 342 has a cross-sectional shape in the form of a right angle triangle, with outer facing sides 342a and 342b and an inner facing side (or hypotenuse) 342c. Generally speaking, whilst first portion 340 may be larger in cross sectional area than second portion 342, the ratio of the lengths of each side may be the same, i.e. the ratio of the length of side 340a to side 340b to side 320c is the same as the ratio of the length of side 342a to side 342b to side 324c.
The first end 344 of mandrel 336 may be affixed to inner pulley 346 of mandrel movement apparatus 338 by any suitable method such as bolts or welding such that mandrel 336 will rotate and translate with inner pulley 346. Whilst not shown in the FIGS., the second end 347 of mandrel 336 may be supported for rotational and translational movement by any suitable attachment mechanism.
As depicted in
Further, the respective inner sides 340c, 342c of first and second portions 340, 342 define a blank receiving slot 350. Blank receiving slot 350 may have a first configuration for receiving/releasing blank 100 and a second configuration for holding blank 100. In the first configuration blank receiving slot 350 may be slightly larger than the thickness of blank 100. In the second configuration, through movement of first portion 340 and/or second portion 342 of mandrel 336, the gap between inner facing side 340c and inner facing side 342c (
With reference to
Mandrel movement apparatus 338 includes a vertically orientated support tube 354 that may be generally rectangular. Inner pulley 346 (to which mandrel 336 is connected to) is rotatably mounted to support tube 354 (
Affixed to the rear of support tube 354 is a vertically extending rail 356 (
In order to move mandrel 336 vertically (in the Z-direction in
With reference to
With this arrangement, operation of servo motor 362 will drive movement of belt 366 causing movement of support tube 354 relative to support bracket 360 (along rail 356) such that the vertical position in the Y-direction of support tube 354 and interconnected mandrel 336 can be adjusted can be adjusted relative to frame 214.
The following will be appreciated in particular:
Also associated with mandrel movement apparatus 338 is a generally vertically oriented caterpillar device 374 which may be generally similar to caterpillar devices 310 and 312 described above. Caterpillar device 374 may have a hollow cavity housing hoses and wires carrying pressurized air/vacuum and electrical/communication wires. Caterpillar device 374 allows such hoses and wires to move longitudinally as the support tube 354 is moved vertically and horizontally.
The caterpillars allow hoses and wires to supply mandrel movement apparatus 338. In this way both pressurized air/vacuum and/or electrical communication wires may be brought form locations external to the frame 214 onto the moving mandrel movement apparatus 338. An example of suitable caterpillar devices that could be employed is the E-Chain Cable Carrier System model #240-03-055-0 made by Igus™ Inc It should be noted that electrical communication between the PLC 500 and the mandrel movement apparatus 338 could in other embodiments be accomplished using wireless technologies that are commercially available.
As previously referenced, mandrel movement apparatus 338 is also configured such that mandrel 336 may rotate about a generally horizontally orientated axis of rotation 352 shown in
In some embodiments, mandrel movement apparatus 338 may also be configured to allow mandrel 336 to move in the horizontal Y directions, i.e., in the Y1, Y2 directions indicated in
It will be appreciated that if the speeds and directions of the motors 362, 370 are varied in different manner, then the motion of the support tube 354 (mandrel 336) can be created that has both a vertical component as well as a horizontal component. Thus, any desired path within these two degrees of freedom (vertical in the Z direction and horizontal in the Y direction) can be created for support tube 354—and thus for mandrel 336 (such as a path having curved path portions). At the same time, through operation of motor 370, mandrel 336 may rotate about axis 352. Thus, by controlling the rotational direction and speed of the motors 362, 370 independently of each other, PLC 500 can control movement of mandrel 336 along any path within these two degrees of freedom, within the physical constraints imposed by a pair of bump stops 376, 378 at either end of rail 356 (
Encoders may be provided for motors 362, 370 which may be in communication with, and provide signals through the servo drive to PLC 500. The encoder may be similar to as described above for motor 286a. Thus PLC 500 can in real time know/determine/monitor the position of the belt 366 in space and thus will determine and know the position of the mandrel 336 in the Z-direction at any given time and will also determine and know the rotational position of mandrel 336 about axis 352.
The sequence of steps 1000(1) to 1000(10) in
At step 1000(1), through control of mandrel movement apparatus 338 by PLC 500, mandrel 336 may be positioned as shown, such that blank receiving slot 350 is generally orientated horizontally and is also horizontally aligned with blank 100 on conveyor 220. Blank receiving slot 350 may also be in its first configuration as described above.
At step 1000(2), as blank 100 in advanced on belt 316 direction 229, edge 100b of blank 100 will enter blank receiving slot 350. At the same time, as blank 100 advances past scoring roller 222 and adhesive applicator apparatus 224, through operation by PLC 500, folds 102-112 are formed scoring roller 222 and adhesive may be applied by adhesive applicator apparatus 224 to the portions upper surface of blank 100 as described above. As a portion of blank 100 enters blank receiving slot 350, blank receiving slot 350 may move to its second configuration as described above such that mandrel 336 engages a portion of panel A of blank 100.
With reference to
First, through steps 1000(2) to 1000(4) (
At step 1000(4) (
Mandrel 336 may then rotate a further 90 degrees in a clockwise direction to the position shown at 1000(6). During rotation of mandrel 336, panel C (along with panels A and B) may be rotated 90 degrees relative to panel D about the fold line 106 between adjacent panels C and D such that side 340b of first portion 340 is in contact with panel D.
The configuration in 1000(6) is shown in more detail in
Subsequently, mandrel 336 may rotate a further 90 degrees in a clockwise direction to the position shown at 1000(7). During rotation of mandrel 336, panel D (along with panels A, B and C) may be rotated 90 degrees relative to panel E about the fold line 108 between adjacent panels D and E. As shown in
Through control of mandrel movement apparatus 338 by PLC 500 during the 90 degree rotational movement of mandrel 336 between 1000(6) and 1000(7) and each 90 degree rotation thereafter mandrel 336 may also move vertically in the Z1 direction (
In some embodiments, rather than mandrel 336 moving vertically in the Z1 direction as described above, conveyor 220 may be configured to move vertically in the Z2 direction (
Following each rotational and vertical (in the Z1 direction) movement of mandrel 336 and before the subsequent rotational and vertical (in the Z1 direction) movement, mandrel 336 may also move vertically in the Z2 direction in order to compress parallel panels that have just been placed into contact with each other. This may ensure sufficient contact between parallel panels such that the adhesive may secure the two panels together. In some embodiments, movement of mandrel 336 may be paused to allow the adhesive to dry or cure sufficiently.
Through steps 1000(7) to 1000(9) (
At step 1000(10), mandrel 336 may disengage from panel A (i.e., by moving from its second configuration to its first configuration) and may also be moved in the Y1 (
Under control of PLC 500, mandrel 336 may then be moved in the Y2 and Z2 directions and also be rotated about axis 352 back to the position of step 1000(1) by mandrel movement apparatus 338 and conveyor may move such that ridge 318 or 318b is in the position shown at step 1000(1). Another blank 100 may then be positioned on conveyor 210 by first movement apparatus 218a and the steps 1000(1) to 1000(10) may be repeated in order to form another pallet runner 150.
In some embodiments, the one or more fold lines may be formed on blank 100 prior to the application of adhesive. In other embodiments, adhesive may be applied to blank 100 prior to formation of the one or more fold lines.
In some embodiments, blanks 100 may arrive at runner forming station 210 (or at runner blank conveyor 202) with some or all of the fold lines already formed and/or an adhesive already applied. For example, system 200 may include a separate scoring subsystem to form the one or more fold lines and/or a separate adhesive application subsystem to apply adhesive to some or all of the upper surface of blank 100.
In some embodiments, it may not be necessary for mandrel 336 to be moved in the Z1/Z2 directions. For example, if conveyor belt 316 ended prior to mandrel 336, such that mandrel 336 is not positioned over belt 316 (i.e., mandrel 336 is positioned adjacent to belt 316), the unfolded portion of blank 100 may flex to compensate for the growing thickness of the partially formed runner.
In embodiments where conveyor belt 316 ends prior to mandrel 336, such that mandrel 336 is positioned adjacent to belt 316, the formed runner 150 may simply fall off mandrel 336 or be pulled off mandrel 336. The runner 150 may be pulled off mandrel 336 by a suitable apparatus, such as by another conveyor operating in a generally perpendicular direction to conveyor 220 (i.e., the Y2 direction in
The mandrel 336 is only one example of a gripper that may be used to rotate the panels. In some embodiments, the gripper may be configured to engage blank 100 in different manner than described above. For example, the gripper may be configured to engage a smaller portion of panel A only, for example at one end, before rotating as described above to form runner 150. In some embodiments, the gripper may be configured to engage and rotate opposed ends of panel A only.
In some embodiments, the gripper may be configured to engage a runner template. The runner template may be an elongated structure, that is affixable to panel A (such as by adhesive) which is rotated by the gripper. For example, the runner template may be a rectangular tubular structure made from cardboard or plastic. Once the runner template is affixed to panel A, the gripper will rotate the runner template and the affixed panel A to form a runner, i.e., the runner temple substantially performs the same function as mandrel 336, but also forms an integral part of the runner. The runner template may add additional strength and rigidity to the formed runner. Further, if it is desirable to manufacture runners with different cross-sectional profiles, it may be easier, quicker and more economical to change to use a different runner template rather than a different mandrel.
In other embodiments, runner forming station 210 may be configured to form runners of different cross sectional profiles, such as runner 150′ depicted in
In order to form runner 150′, panel rotating apparatus 226 may still include a gripper configured to engage panel A′ and through a series of rotational and vertical movements, form the spiral structure of runner 150′. However, mandrel 336 may be configured in a different manner to as described above to form runner 150. For example, the mandrel may instead comprise a single portion with a generally rectangular cross section with and outer surface which is configured to engage panel A (such as by one or more suction cups on the outer surface of the mandrel). Similar to as described above for the mandrel may, through a series of rotational and vertical movements, form the spiral structure of runner 150′.
At pallet assembly station 212 one or more runners 150 may be secured to a deck 170 on deck conveyor 204 to form a corrugated pallet 160. Completed pallets 160 may be transferred and stacked on takeaway conveyor 208.
Deck conveyor 204 is shown in isolation in
The presence of a stack of decks 170 at the second position 212 may be detected by a sensor 550 (
Second engagement head 216b may be configured to engage a complete runner 150 from runner forming station 210 and, through second movement apparatus 218b transfer runner 150 to pallet assembly station 212.
With reference to
Second engagement head 216b is shown in greater detail in
Suction cups 410 may be similar to suction cups 254 described above and may each be interconnected to a vacuum generator 520 as described above. Each vacuum generator 520 be interconnected to a hose (not shown) that is in turn interconnected to one or more vacuum solenoid valve devices 530, which operate as described above and are in electronic communication with PLC 500 and controlled by PLC 500 such that PLC 500 can turn on and off the supply of vacuum force to the suction cups 410.
In some embodiments, upper and lower suction plates 402, 404 (and suction cups 410) may be configured rotational movement about a generally vertical axis of rotation 408 (
In some embodiments, second engagement head 216b may include a shock absorbing mechanism 420 which functions to absorb forces between upper and lower suction plates 402, 404 and sprocket 406. This may be beneficial in preventing damage to the components of second engagement head 216b, second movement apparatus 218b and any items engaged by second engagement head 216b during operation. Shock absorbing mechanism 420 may be any suitable mechanism operable to perform these functions, such as a spring mechanism.
Similar to first engagement head 216a, second engagement head 216b may also have a dedicated movement apparatus, second movement apparatus 218b. Second movement apparatus 218b may generally be configured similarly to first movement apparatus 218a described above such that second engagement head 216b may move in both the vertical Z and horizontal X/Y directions (i.e., directions parallel to axes Z, X and Y in
In order to drive second movement apparatus 218b horizontally (in the X-direction in
With reference to
Through operation of second movement apparatus 218b, second engagement head 216b may be moved towards a completed pallet runner 150 at runner forming station 210 (
In some embodiments, pallet runner 150 may have a layer of adhesive applied to the surface being brought into contact with deck 170. Alternatively or additionally, deck 170 may have layer(s) of adhesive applied on surface 172 where pallet runners(s) will be situated. The layer of adhesive may be applied by a suitable adhesive applicator apparatus 422 (not shown in FIGS.). The adhesive application apparatus may be similar to adhesive applicator apparatus 224 described above and may apply a layer of any suitable adhesive such as those described above.
As runner 150 is bought into contact with deck 170, downwards pressure may be applied to pallet runner 150, through second engagement head 216b by downwards movement of support 256b of second movement apparatus 218b in order to ensure that the later of adhesive contacts both of the surfaces being bought into contact. This may be desirable when the later of adhesive comprises a pressure sensitive HMA. At this stage, second movement apparatus 218b may pause movement and hold pallet runner 150 in place on deck 170 for a period of time (also known as the contact time). Depending on the type of adhesive being used, this may be necessary to allow the adhesive to cure or set such that surface of pallet runner 150 and deck 170 are adhered together.
Suction cups 410 will then disengage and release the engaged pallet runner 150 from engagement with second engagement head 216b. The steps described above, where second engagement head 216b returns to runner forming station 210 to pick up another completed runner 150 and places the runner 150 on deck 170 may be repeated until corrugated panel 160 is completed. Once corrugated pallet 160 is completed, second engagement head 216b may move to a home or idle position so as not to interfere with the subsequent movement of corrugated pallet 160.
Whilst as shown in
Whist corrugated pallet 160 as shown in the FIGS. is comprised of three runners 150 and a deck 170, in some embodiments the pallet may also include an additional deck such that the runners 150 are sandwiched on opposed sides by a deck 170. A second deck 170 may be introduced using any suitable method. For example, a second stack of decks (which may be generally the same size as decks 170) may introduced by a separate panel conveyor (which may be similar to blank conveyor 204 described above) and a single deck may be transferred engagement with a suitable engagement head (which may be similar to second engagement head 216b), moved by a suitable movement apparatus (which may be similar to second movement apparatus 218b) into contact with the runners 150 that have already been assembled with deck 170. Adhesive may be applied to the deck or the contacting surfaces of runners 150 as described above.
Takeaway conveyor 208 is shown in isolation in
The presence of a stack of corrugated pallets 160 at the at first position 438 may be detected by a sensor 560 (
In some embodiments, completed corrugated pallets 160 may be transferred by takeaway conveyor 208 for the loading/packaging of items onto each pallet 160.
In some embodiments, corrugated pallets 160 may be transferred by takeaway conveyor 208 for additional manufacturing/processing steps, such as for example the addition of additional panels or runners to corrugated pallet 160 or for the application of a protective coating to pallets 160.
Third Engagement Head 216c/Third Movement Apparatus 218c
Transfer of corrugated pallets from pallet assembly station 212 to the first position 438 of takeaway conveyor 208 may be affected by third engagement head 216c and third movement apparatus 218c.
With reference to
Similar to first and second engagement heads 216a, 216b, third engagement head 216c may also have a dedicated movement apparatus, third movement apparatus 218c. With reference to
Third movement apparatus 218c may generally be configured similarly to first and second movement apparatuses 218a, 218b described above such that third engagement head 216c may move in both the vertical Z and horizontal X/Y directions (i.e., directions parallel to axes Z, X and Y in
In operation, through operation of third movement apparatus 218c, third engagement head 216c may be moved towards a completed corrugated pallet 160 at pallet assembly station 212, where a portion of corrugated pallet 160 may be engaged one or more suction cups on third engagement head 216. The air suction force that may be developed at the outer surfaces the suction cups will be sufficient so that when activated they can engage corrugated pallet 160 and as third movement apparatus 218c moves third engagement head 216c with engaged corrugated pallet 160 from the runner forming station 210 to the first position 438 of takeaway conveyor 208. This process may be repeated as additional corrugated pallets 160 are completed at pallet assembly station 212, forming a stack of corrugated pallets 160 at the first position 438 of takeaway conveyor 208. Once the stack reaches a predetermined number of pallets 160, takeaway conveyor 208 may be activated to move the stack from the first position 438 to the second position 440.
The operation of system 100 will now be described in detail. A plurality of runner blanks 100 may be presented in vertically and transversely oriented stacked arrangement on a pallet 242 at first position 236 on runner blank conveyor 202 (
PLC 500 causes runner blank conveyor 202 to be operated to move and transfer the stack of runner blanks 100 on pallet 242 from first position 236 to second position 238 (
At this stage, runner forming station 210 may be configured as shown in
At this stage, PLC 500 has also operated deck conveyor 204 such that the stack of decks on pallet 242 have been moved from first position 380 to second position 212.
Next, under control of PLC 500, second movement apparatus 218b is activated to move second engagement head 216b to the completed runner 150 at runner forming station 210. PLC 500 then activates suction cups 410 such that second engagement head 216b engages runner 150. Second movement apparatus 218b then moves the engaged runner to pallet assembly station 212 and places runner 150 on the uppermost deck 170 in the stack of decks at second position/pallet assembly station 212.
As second movement apparatus 218b moves an engaged runner to pallet assembly station 212, PLC may activate applicator apparatus 422 to apply a layer adhesive to a surface of the engaged runner and/or to a portion of the upper surface of the uppermost deck 170 in the stack of decks.
Further, as second movement apparatus 218b moves an engaged runner to pallet assembly station 212, under control of PLC 500 second movement apparatus 218b may rotate second engagement head 216b and the engaged runner about axis 408 (
Once runner 150 is placed on deck 170, second engagement head 216b may remain engaged to runner 150 and second movement apparatus 218b may pause movement for a period of time, in order to allow the layer of adhesive between the contacting surfaces sufficient time to adhere. In some embodiments, the second movement apparatus 218b may be operated by PLC 500 such that runner 150 exerts a degree of downward pressure on deck 170 to ensure the adhesive will sufficiently adhere to the contacting surfaces of runner 150 and deck 170.
Next, PLC 500 then deactivates suction cups 410 such that second engagement head 216b can disengage from runner 150. Second movement apparatus 218b may then move second engagement head 216b away from runner forming station 210 and may return to pick up another runner 150 from runner forming station 210.
The above steps may be repeated until the required number of runners have been orientated and added to deck 170 and a completed corrugated pallet 160 is formed.
Next, under control of PLC 500, third movement apparatus 218c is activated to move third engagement head 216c to the completed corrugated pallet 160 at pallet assembly station 212. PLC 500 then activates suction cups 442 such that third engagement head 216c engages corrugated pallet 160. Third movement apparatus 218c then moves the engaged pallet to the first position 438 of takeaway conveyor 208 and places corrugated pallet 160 at first position 438.
Next, PLC 500 then deactivates suction cups 442 such that third engagement head 216c can disengage from corrugated pallet 160. Third movement apparatus 218b may then move third engagement head 216c away from first position 438 of takeaway conveyor 208 and may return to pallet assembly station 212 to pick up another corrugated pallet 160.
The foregoing cycle can be repeated multiple times to form multiple corrugated pallets 160. It is anticipated that corrugated pallets may be formed at a rate of in the range of about 10 to about 20 corrugated pallets per minute depending on the overall dimensions and configuration (e.g., number or runners or decks) of the corrugated pallets and the size of the machine but other rates of operation are also possible and contemplated.
After the stack of blanks 100 on pallet 242 at second position of runner blank conveyor 202 is exhausted, PLC 500 may cause runner blank conveyor 202 to be operated to move and transfer the empty pallet 242 from second position 238 to third position 240 to be stacked by pallet stacking apparatus 244. In some embodiments, sensor 540 (
Similarly, after the stack of decks 170 on pallet 242 at second position/pallet assembly station 212 of runner deck conveyor 202 is exhausted, PLC 500 may cause deck conveyor 202 to be operated to move and transfer the empty pallet 242 from second position 238 to third position 382. In some embodiments, sensor 550 (
Sensor 560 (
The stack of corrugated pallets at second position 440 may be moved away to another location and may subsequently be loaded with one or more items/articles.
In some embodiments, PLC 500 may be programmed, such as by a user at HMI 510 with the number of runner blanks 100 and/or the number of decks 170 provided and system 200 may operate until all runner blanks 100 and/or of decks 170 have been exhausted.
PLC 500 may be configured to coordinate the components of system 200, such that system 200 may continuously and efficiently produce corrugated pallets 160. By way of example, PLC may ensure that as a runner 150 is completed at runner forming station 210, second engagement head 216a is in position to engage the completed runner, through coordination of runner forming station 210 and second movement apparatus 218b. At the same time, first movement apparatus 218a may position first engagement head 216a, with an engaged runner blank 100 proximal to runner forming station 210, such that runner forming station 210 can quickly receive runner blank 100 after a completed runner 150 is removed.
In some embodiments, runners 150 may be arranged in different configurations on a corrugated pallet, for example using different numbers or arrangements of runners 150 on deck 170. This may be desirable for a number or reasons, for example to increase the strength of the corrugated pallet or to accommodate different forks of lifting equipment. For example, when a pallet is required to support a heavier load, a greater number of runners may be used.
Furthermore, in some embodiments the thickness of runner blank 100 and/or deck 170 may varied to alter the properties of corrugated pallet 160. For example, a thicker material may be used to increase the strength and/or durability of corrugated pallet 160. PLC 500 may be pre-programmed to make adjustments to the operation of other components in system 200 to account for changes in the thickness of runner blank 100 and/or deck 170, in particular to the operation of motors 362 and 370 of panel rotating apparatus and motor 324 of scoring roller 320.
In some embodiments, system 200 may be configured to produce a four way pallet that may be accessed from any side by a fork lift. In such configurations the pallet may include shortened runners. These runners may be produced from runner blanks having a shorter length or by the cutting a longer runner (such as runner 150). The runner may be cut using any suitable method, such as die cutting.
An example of a four way pallet 660 is shown in
When assembled, pallet 660 includes a pair of spaced apart parallel openings 664 (similar to pallet 160) and also a pair of spaced apart parallel openings 666, defined by the spaces between adjacent pallet runner blocks. Through this arrangement the forks of equipment such as a front-end loader or forklift truck to be inserted either of the spaces 664, 666 such that the pallet and its supported load may be lifted and moved.
In various embodiments, the spacing and length of pallet runner blocks 650a-c, 652a-c and 654a-c may be varied.
Each of the pallet runner blocks 650a-c, 652a-c and 654a-c may be constructed and formed in a similar manner to pallet runner 150 described above. In an embodiment, pallet runner blocks 650a-c, 652a-c and 654a-c are formed from a pallet runner 150 that has been cut into smaller blocks, such as by die cutting. In other embodiments, pallet runner blocks 650a-c, 652a-c and 654a-c may be formed individually on a pallet forming system, such as pallet forming system 200 described above from a suitably sized blank.
Another example of a four way pallet 760 is shown in
In various embodiments, the spacing and depth of cut out portions 752a-c, 754a-c may be varied.
When assembled, pallet 760 includes a pair of spaced apart parallel openings 764 (similar to pallet 160) and also a pair of spaced parallel openings 766, defined by the spaces between adjacent pallet runner blocks. Through this arrangement the forks of equipment such as a front-end loader or forklift truck to be inserted either of the spaces 764, 766 such that the pallet and its supported load may be lifted and moved.
Pallets 660, 670 may be manufactured from planar blanks on a pallet forming system, such as a modified version of pallet forming system 200.
In some embodiments pallets 660, 760 may comprise a second deck secured to the opposite side of the runners/runner blocks to that of decks 670, 770.
In some embodiments, runner blank 100 may be a different material to deck 170.
In some embodiments, blank 100 is a single wall “A” flute sheet that is between about 20 and about 46 inches long and between about 24 inches and about 54 inches wide. In an embodiment blank 100 is about 38 inches long and about 46 inches wide.
In some embodiments runner 150 is between about 30 and about 46 inches long, between about 2 inches and about 5 inches high and between about 1.5 inches and about 3.5 inches wide. In an embodiment blank 100 is about 46 inches long, about 2.5 inches high and about 2.5 inches wide.
In some embodiments, deck 170 is “BC” flute sheet that is between about 36 and about 50 inches long and between about 40 inches and about 62 inches wide. In an embodiment blank 100 is about 42 inches long and about 48 inches wide.
In various embodiments, system 200 may be configured to form corrugated pallets 160 having a length of between about 30 inches and about 50 inches, a width of between about 30 inches and about 50 inches and a height of between about 2.75 inches and about 5 inches. In an embodiment pallet 160 has a length of 40 inches, a width of 40 inches and a height of 3.5 inches.
In some embodiments where system 200 is configured to produce corrugated pallets where the runners 150 are sandwiched by a deck 170 on opposed sides, the pallet may have a length of between about 38 inches and about 54 inches, a width of between about 34 inches and about 50 inches and a height of between about 3 inches and about 5 inches. In an embodiment the pallet has a length of 46 inches, a width of 42 inches and a height of 4.1 inches.
As discussed above, when it is desired to change the type/configuration of runner and/or corrugated pallet to be formed, using a different type/configuration of runner blank, pallet forming system 200 can be quite easily modified. For example, one mandrel 336 can be replaced by a differently configured mandrel. By using a mandrel with a different cross-sectional profile (i.e., different to the rectangular outline 348 described above for mandrel 336), pallet runners of different sizes of cross sectional shapes may be formed such as triangular, square, pentagonal or hexagonal. PLC 500 may be pre-programmed to make adjustments to the operation of other components, in particular to the operation of motors 362 and 370 of panel rotating apparatus and motor 324 of scoring roller 320. Thus by an interchange of mandrel 336 to provide for alternate configurations of the pallet runner, PLC 500 and its operation components of runner forming station 210 may be appropriately programmed and thus different sized and configurations of pallet runners may be formed.
Of particular note, each stack of blanks 100 on runner blank conveyor 202 may have associated information that can be read by an information reader 570 (
The structural/mechanical components of system 200 may be made from any suitable materials. For example, frame members, and many of the parts that make up the engagement heads 216a-c, movement apparatuses 218a-c, conveyors 202, 204, 206 may be made of steel or aluminium, or any other suitable materials. Aluminum is particularly suitable for most parts. However, plates that hold the suction cups on the engagement heads and flanges that mount on gearbox shafts can be made from stainless steel for strength and hardness. Parts and components may be attached together in conventional ways such as for example by bolts, screws, welding and the like.
An embodiment as disclosed herein relates to a method of forming an elongate pallet runner from a planar blank comprising a plurality of adjacent panels. The method comprises: engaging a first panel of the plurality of adjacent panels at a first end of the blank with a gripper, rotating the gripper and the engaged first panel, causing rotation of each of the plurality of adjacent panels relative to its adjacent panel, to thereby form an elongate pallet runner around an outer portion of the gripper with a continuous spiral structure that is nested, each panel having a planar surface that abuts against a planar surface of another panel, and disengaging the first panel from the gripper.
In some embodiments, the method further comprises engaging an upper surface of the planar blank with a scoring apparatus to form the plurality of adjacent panels by scoring a plurality of parallel spaced apart fold lines, a respective fold line separating each of the adjacent panels.
In some embodiments, the method further comprises applying an adhesive to a surface of at least one of the plurality of adjacent panels.
In some embodiments, the gripper comprises a mandrel.
In some embodiments, as the gripper is rotated, the gripper is also moved vertically in a direction perpendicular to an upper surface of the planar blank. In some embodiments, for each 90 degree rotation of the gripper, the gripper is moved vertically a distance equal to about a thickness of the planar blank.
An embodiment as disclosed herein relates to an apparatus for forming an elongate pallet runner from a planar blank comprising a plurality of adjacent panels. The apparatus comprises a gripper configured to engage a first panel of the plurality of adjacent panels at a first end of the blank, wherein rotation of the gripper and the engaged first panel causes rotation of each of the plurality of adjacent panels relative to its adjacent panel, so as to form an elongate structure with a continuous spiral structure that is nested, each panel having a planar surface that abuts against a planar surface of another panel.
In some embodiments, the apparatus further comprises a scoring apparatus configured to form the plurality of adjacent panels by scoring a plurality of parallel spaced apart fold lines, a respective fold line separating each panel and its adjacent panel. In some embodiments, the scoring apparatus comprises a scoring roller.
In some embodiments the apparatus further comprises an adhesive applicator apparatus configured to apply an adhesive to a surface of at least one of the plurality of adjacent panels.
In some embodiments the apparatus further comprises a conveyor configured receive the planar blank and to advance the planar blank in a linear direction towards the gripper. In some embodiments, the conveyor comprises an engagement feature to retain the planar blank in position on the conveyor.
In some embodiments, the gripper is rotated by a movement apparatus. In some embodiments, the movement apparatus is also configured to move the gripper vertically in a direction perpendicular to an upper surface of the planar blank
In some embodiments, the gripper comprises a mandrel. In some embodiments, the mandrel has an outer portion having a cross-sectional shape that provides a template for the elongated pallet runner to be formed around. In some embodiments, the mandrel comprises a first portion and second portion, wherein the first and second portion define a blank receiving slot configured to receive a portion of the first panel.
In some embodiments, the blank receiving slot has a first configuration and a second configuration, wherein in the first position the first panel is disengaged with the mandrel and in the second position the first panel is engaged with the mandrel.
An embodiment as disclosed herein relates to a system for forming a pallet. The system comprises a runner forming station operable to receive a plurality of planar blanks and form a plurality of elongate pallet runners from the planar blanks. Each of the elongate pallet runners comprises a plurality of panels, each panel bent relative to an adjacent panel to form a continuous spiral structure having a cross-sectional profile that is nested, each panel having a planar surface that abuts against a planar surface of another panel. The system further comprises a pallet assembly station operable to receive a deck and a plurality of pallet runners from the runner forming station, a first engagement head operable to engage one of the plurality of pallet runners and a first movement apparatus operable to move the first engagement head between the runner forming station and the pallet assembly station to move the engaged pallet runner from the runner forming station to the pallet assembly station and to place the engaged pallet runner on a surface of the deck.
In some embodiments, the system further comprises a second engagement head configured to engage a planar blank from a stack of planar blanks and a second movement apparatus configured to move the second engagement head between the stack of planar blanks and the runner forming station to move the engaged planar blank from the stack of planar blanks to the runner forming station.
In some embodiments, the system further comprises a third engagement head configured to engage a pallet at the pallet assembly station and a third movement apparatus configured to move the third engagement head between the pallet assembly station and a stack of pallets to move the engaged pallet from the pallet assembly station to the stack of corrugated pallets.
In some embodiments, the system further comprises an adhesive applicator apparatus configured to apply an adhesive to a surface of the engaged pallet runner or to the surface of the deck before the engaged pallet runner is placed on the surface of the deck by the first movement apparatus.
The above-described embodiments are intended to be illustrative only and in no way limiting. The described embodiments of carrying out the invention are susceptible to many modifications of form, arrangement of parts, details and order of operation. Other variations are possible.
When introducing elements of the present invention or the embodiments thereof, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
