ROBOTIC STRAPPING MACHINE WITH PIVOTING STRAPPING HEAD AND METHOD

Abstract

A strapping system is mountable to an end effector of a robotic arm for automatically applying strapping to an object. The strapping system has: a frame; a strapping head mounted to the frame; a fixed vertical track section mounted to the frame; a lower track section mounted to the frame below the strapping head; an upper track section mounted to the frame above the strapping head; and, a movable track section mounted to a distal end of one of the upper or lower track sections.

Description

BACKGROUND OF THE DISCLOSURE

The present exemplary embodiment relates to strapping machines. It finds particular application in conjunction with automated strapping machines, and will be described with particular reference thereto. However, it is to be appreciated that the present exemplary embodiment is also amenable to other like applications.

Plastic or metal strapping (also sometimes referred to as banding) is commonly used to bind together shipping pallets and/or the goods supported thereon. Strapping is also used in other applications where items are to be bound together. For example, strapping is often used to secure a roll of paper of other material to prevent unraveling during shipping, transport and/or storage.

In a machine for strapping a shipping pallet, together with goods supported by the shipping pallet, one or more steel or plastic straps are passed around and/or through the shipping pallet and/or the goods, tensioned, and overlapping portions of each strap are secured together, such as by welding or crimping or other suitable methods. In a typical application, a number of such straps are secured about the shipping pallet and/or goods in orthogonal planes. While manual application of strapping is possible, automated systems generally will also include a feeding conveyor or other transport positioning the shipping pallet with goods supported thereon for automatic application of the strapping.

In such automatic systems, typically one or more strap guides may be of a fixed configuration. Such machines may often have one or both of a vertical or horizontal strap guide in the form of an elongate channel. The strap guides generally form a loop or perimeter around which the strapping is configured to travel such that any object (e.g., a shipping pallet, etc.) placed within the loop is in position to be surrounded by the strapping. Basic fixed strapping machines have been in use for many years, and provide adequate strapping functionality in settings where strapping orientation is static and/or the goods strapped to the shipping pallet are of a uniform size.

It has also been known to strap coiled material (e.g., sheet metal coil, paper coil, etc.) by securing strapping around an outside diameter of the coil or by feeding a steel or plastic strap through the central opening or bore of the coiled material, tensioning the strap to form a tensioned loop around multiple layers of the coiled material, and securing the strapping. Exemplary machines for applying strapping to coils in the latter configuration generally include a pair of adjustable strap-guiding arms and an adjustable strapping head for tensioning and securing the strapping. The strap-guiding arms are selectively positionable within the central opening of the coiled material, and the strapping head is operative for feeding the strap along the path defined by the strap-guiding arms when positioned within the central opening of the coiled material. The strapping head is further configured to tension the strap, sever the tensioned loop, and secure the loop in applying a steel seal to the tensioned loop. These devices are limited in use to strapping a single roll of material.

Automated strapping of multiple coils of material has heretofore been performed manually by manually passing strapping through the central bores of two coils of material, tensioning the strapping, and securing the same. Manual strapping is time consuming and can be difficult to perform when strapping large coils.

Thus, there is a need for an improved strapping machine which overcomes the above mentioned difficulties of others while providing better overall results.

SUMMARY OF THE DISCLOSURE

in accordance with one aspect of the present disclosure, a strapping system mountable to an end effector of a robotic arm for automatically applying strapping to at least one associated object comprises a frame, a strapping head mounted to the frame, a fixed vertical track section mounted to the frame, a lower track section mounted to the frame below the strapping head, an upper track section mounted to the frame above the strapping head, and a movable track section mounted to a distal end of one of the upper or lower track sections, the movable track section movable from a first open position to a second closed position, the movable track section cooperating with the lower track section, the upper track section and the vertical track section when in the second closed position to form a chute for advancing strapping around the at least one associated object.

The movable track section can extend parallel to the track section to which it is mounted in the first open position, and the movable track section can extend perpendicular to the track section to which it is mounted in the second closed position. The system can include at least one track actuator for moving the movable track section between the first open position and the second closed position. At least one retention member can be provided for securing the movable track section in the second closed position. The retention member can include at least one gas strut. The strapping head can be pivotally secured to the frame for tilting movement relative to the vertical track section. The strapping head can pivot between vertical and horizontal orientations. The system can further include a strapping head actuator supported by the frame, the strapping head actuator operatively connected between the frame and the strapping head for effecting tilting movement of the strapping head.

In accordance with other aspect of the disclosure, a strapping system comprises a strapping chute for advancing an associated strapping material around and object to be strapped, and a strapping head, the strapping chute and the strapping head being supported by a frame mountable to an end effector, wherein the strapping head is pivotally secured to the frame for tilting movement relative to the chute.

The strapping head can be pivotally secured to the frame. The strapping chute can include a vertical track section mounted to the frame, and the strapping head can be pivotable about a non-vertical axis such that the strapping head can be tilted relative to the vertical track section. The system can further include a strapping head actuator supported by the frame, the strapping head actuator operatively connected between the frame and the strapping head for effecting tilting movement of the strapping head.

In accordance with another aspect of the disclosure, a method of strapping an object comprises positioning a strapping system adjacent the object, the strapping system having a frame, a strapping head mounted to the frame, a fixed vertical track section mounted to the frame, a lower track section mounted to the frame below the strapping head, an upper track section mounted to the frame above the strapping head, a movable track section mounted to a distal end of one of the upper or lower track sections, the movable track section movable from a first open position to a second closed position, the movable track section cooperating with the lower track section, the upper track section and the vertical track section when in the second closed position to form a chute for advancing strapping around the at least one associated object, advancing the upper and lower track sections into position on opposing sides of the object with the movable track section in the first open position, moving the movable track section to the second closed position, advancing strapping material through the chute to surround the object, tensioning the strapping material with the strapping head, and severing the strapping material with the strapping head.

Still other aspects of the disclosure will become apparent upon a reading and understanding of the following detailed descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of automated strapping system in accordance with one embodiment of the disclosure.

FIG. 2 is a perspective view of a track actuator where a movable track position is in a first open position in accordance with another embodiment of the disclosure.

FIG. 3 is a perspective view of a track actuator where a movable track section is in a second closed position.

FIG. 4. is another perspective view of the track actuator here the movable track portion is in a first open position.

FIG. 5 is a perspective view of the strapping system with a movable track section in a closed position.

FIG. 6 is a perspective view of the strapping system of FIG. 5 with a strapping head in a tilted position.

FIG. 7 is another perspective view of the strapping system of FIG. 5 with a strapping head in a tilted position.

FIG. 8 is another perspective view of the strapping system of FIG. 5 with a strapping head in a tilted position.

DETAILED DESCRIPTION OF THE DISCLOSURE

With reference to FIG. 1, an exemplary automated strapping system 10 is illustrated including a robot R1 supporting a strapping system 12 in accordance with the present disclosure. The robot R1 includes an articulated robotic arm A1 to which an end effector E1 is mounted. The end effector E1 is supported by the robotic arm A1 for movement in the X-Y-Z dimensions, as well as rotation relative to the robotic arm A1 to which it is attached. This configuration allows virtually limitless positioning and/or orientation of the end effector E1 with respect to the object or objects to be strapped.

In the illustrated embodiment, the object to be strapped includes a box B supported on a shipping pallet SP, which in turn is supported on rollers 16 (or a conveyor or other surface). It should be appreciated that the box B is exemplary in nature and that a wide variety of items can be supported on the shipping pallet SP such as, for example, multiple boxes, equipment, parts, etc. As is conventional, the shipping pallet SP includes a plurality of slats 18 supported by crossmembers 20. Between each of the crossmembers 20 is a void 22 extending between opposite sides of the shipping pallet SP through which strapping material is to be passed to secure the box B to the shipping pallet SP. That is, the present disclosure provides an automated system for positioning strapping material to form a loop extending through each void 22 and around the box B.

The strapping system 12 includes a frame 30 mounted to the end effector E1. The frame supports a strapping head 34 adapted to draw strapping material from a spool 38 of strapping material. The strapping material S is advanced through several track segments to surround the object(s) to be strapped. The strapping head 34 is configured to tighten the strapping material about the object(s) to be strapped, fasten or otherwise secure the strapping material about the object(s) to be strapped, and sever the strapping material.

In FIG. 1, the strapping machine is shown in an initial position with the box B and shipping pallet SP in position to be strapped. The strapping system 12 includes a fixed vertical track section 42, an upper track section 44 and a lower track section 46. A movable track section 50 is pivotally connected to a distal end of the upper track section 44.

With additional reference to FIGS. 2-4, a track actuator 54 is supported on the upper track section 44 and operatively connected to the movable track section 50 to move the movable track section 50 between a first open position (shown in FIGS. 2 & 4) generally parallel with the upper track section 44 and a second closed position (shown in FIG. 3) generally perpendicular to the upper track section 44. It should be appreciated that the movable track section 50, when in the closed position, defines a generally continuous chute with the other track sections through which the strapping material is configured to be advanced. The actuator 54 can be any suitable actuator, such as an electric, hydraulic, pneumatic or electrohydraulic actuator. While a linear actuator is shown in the exemplary embodiment, in some applications a rotational actuator can be used. One or more gas struts 60 are operatively coupled between the upper track section 44 and the movable track section 50 to maintain the movable track section open/closed position.

Accordingly, the robot R1 is configured to advance the strapping system 12 from the initial position shown in FIG. 1 to a strapping position shown in FIG. 2. In the strapping position, the lower track section 46 extends through one of the voids 22 in the shipping pallet SP while the upper track section 44 extends over the box B. The actuator 54 is then activated to pivot the movable track section 50 to the closed position shown in FIG. 3. In the closed position, the movable track section 50 extends between the upper track section 44 and the dower track section 46. The strapping head 34 is then activated to advance strapping material through the chute to surround the box B and portions of the shipping pallet SP, secure and severe the strapping material from the spool 38. In some embodiments, a tensioning mechanism can be deployed to tension the strapping material prior to securing the strapping material. The strapping material can be secured by various methods, such as by heat or friction welding, for example. The secured strapping material is then severed from the standing portion of the strapping material. As used herein, it will be appreciated that the term tag end is the terminal end of the strapping material that is initially advanced through the chute, while the standing portion of the strapping material is any portion of the strapping material that is not the tag end.

After the strapping is secured and severed, the actuator 54 is activated to pivot the movable track section 50 back to the open position, and the robot R1 retracts to withdraw the lower track section 46 from the void 22. The strapped box B and shipping pallet SP can then be repositioned for acceptance of one or more additional straps, or advanced beyond the system 10 to free the system 10 to install strapping on the next object to be strapped.

In the illustrated embodiment, the movement of the robot R1 between the positions of FIG. 1 and the position of FIG. 2 can be predetermined based on a given pallet size. That is, in some applications the pallet size and items to be strapped to the pallet have predefined maximum dimension, and the robot R1 can be programmed to move the strapping system 12 in a manner to accommodate the maximum predefined size of the objects to be strapped. In other embodiments, it will be appreciated that positioning the track sections can be done using computer vision techniques and/or other positioning methods adapted to locate the voids 22 of a pallet and move the strapping system 12 into position. In one embodiment, the upper and/or lower track sections 44 and 46 can include a sensor to sense when a distal end of the upper and/or lower track sections 44 and 46 extends from an opposite side of the shipping pallet 22.

It should be appreciated that other configurations of the movable track section 50 are possible. For example, in an alternative embodiment the movable track section 54 can be pivotally supported by the lower track section 46 and configured to move between an open position parallel to the lower track section 46 and a closed position perpendicular to the lower track section 46. In another embodiment, the movable track section can be split into two movable track section portions such that each of the upper track section 44 and lower track section 46 have a movable track section portion secured thereto. Each movable track section portion can be movable from a position parallel to the track section to which it is attached to a second position perpendicular to the track section to which it is attached. In this embodiment, the two movable track section portions together define the movable track section by joining together at an intermediate location between the upper and lower track sections when in the closed position.

Although the strapping system 10 of the present disclosure is shown applying strapping in a vertical plane about the box B and the shipping pallet SP, the strapping system 10 can also be utilized for applying strapping horizontally about an object to be strapped. To this end, it will be appreciated that the end effector E1 can be rotated 90 degrees such that the track sections extend in a generally horizontal plane. The robot R1 and strapping system 12 then performs strapping operations as set forth above with the exception being that the lower track section 46 is not extended through a void in the shipping pallet SP.

As noted above, the strapping head 34 can be any suitable strapping head. The exemplary strapping head 34 operates to sever and bond the strap material after it is fed through the chute C and tensioned by strap feeder/tensioner SFT. As will also be appreciated, the strap feeder/tensioner SFT can be any suitable strap feeder/tensioner, such as commercially available units manufactured by Signode Corp, for example.

In some embodiments, multiple strapping systems 12 can be supported by the robot R1 and configured to allow simultaneously applying multiple straps to an object and or to one or more objects. For example, two strapping systems 12 can be supported by the robot R1 and configured to simultaneously apply strapping to the box B and shipping pallet SP via each of voids 22 in one stroke of the robot R1.

Turning now to FIG. 5-8, the strapping system 12 is illustrated in isolation from the robot R1. In each of FIG. 5-7, the strapping system 12 is shown with movable track section 50 in a closed position connecting the upper track section 44 and the lower track section 46. In this configuration, the chute C is generally rectangular in shape. When strapping a box B to a shipping pallet SP, the general rectangular shape of the chute is advantageously sized to generally closely correspond to the size and shape of the box B on the shipping pallet SP. In some instances, however, it may be desirable to strap a box or item to a shipping pallet wherein the box or object is not of a rectangular shape and/or is smaller than the box B. In such instances, the generally rectangular chute C of FIG. 5 may not be optimum because, unlike the strapping material on box B of FIGS. 1-4, the strapping material applied in such other instances will often extend at an angle (e.g., not vertical) when it is tensioned about the object to be strapped. The angled strap material can be difficult to secure.

Accordingly, the strapping head 34 of the present disclosure is mounted to the frame 30 for tilting (e.g., pivoting) movement relative to the frame 30. As best seen in FIGS. 6-8, the strapping head 34 is pivotally connected at a lower end thereof to the frame 30 by pivots 64. Pivots 64 allow the strapping head 34 to tilt inwardly to match, or more closely match, an angle of a strap applied to an object. An strapping head actuator 68 is mounted to the frame 30 and operatively coupled to the strapping head 34 to move the strapping head between a vertical position as shown in FIG. 5 and a tilted position as shown in FIGS. 6-8.

It will be appreciated that when the strapping system 12 is used to strap objects to a shipping pallet wherein the resulting tensioned strapping material is angled relative to vertical, the strapping system 12 is configured to tilt the strapping head 34 to align with the angle of the tensioned strapping material. The strapping material can then be more efficiently secured and severed than would likely be the case if the strapping head remained vertical.

It should be appreciated that aspects of the present disclosure can be used for applying strapping to objects other than objects on pallets. In some applications, the system can be used to apply strapping to products to secure coils of material in the coiled configuration. The system can further include a conveyor or other transport device for advancing products or the like into position for strapping.

The exemplary system in accordance with the present disclosure, therefore, permits application and installation of strapping to many more product types and configurations than prior art fixed-type (e.g., horizontal or vertical) strapping machines.

The exemplary robotic strapping machine of the present disclosure has been designed to have the capability of automatically strapping products together at a variety of load types, orientations, configurations and sizes. The machine is adaptable to use with a wide variety of products and in a wide variety of orientations and departs from standalone machines that can only perform a limited number of functions in a limited or single orientation.

The system of the present disclosure utilizes a robotic arm to make almost unlimited motions to position the track sections for strapping through voids and/or around perimeters of objects, such as coils of material, for example.

The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

Claims

1. A strapping system mountable to an end effector of a robotic arm for automatically applying strapping to at least one associated object, the strapping system comprising: a frame;a strapping head mounted to the frame;a fixed vertical track section mounted to the frame;a lower track section mounted to the frame below the strapping head;an upper track section mounted to the frame above the strapping head;a movable track section mounted to a distal end of one of the upper or lower track sections, the movable track section movable from a first open position to a second closed position, the movable track section cooperating with the lower track section, the upper track section and the vertical track section when in the second closed position to form a chute for advancing strapping around the at least one associated object.

2. The strapping system of claim 1, wherein the movable track section extends parallel to the track section to which it is mounted in the first open position, and wherein the movable track section extends perpendicular to the track section to which it is mounted in the second closed position.

3. The strapping system of claim 1, further comprising at least one track actuator for moving the movable track section between the first open position and the second closed position.

4. The strapping system of claim 3, further comprising at least one retention member for securing the movable track section in the second closed position.

5. The strapping system of claim 4, wherein the retention member includes at least one gas strut.

6. The strapping system of claim 5, wherein the strapping head is pivotally secured to the frame for tilting movement relative to the vertical track section.

7. The strapping system of claim 6, wherein the strapping head can pivot between vertical and horizontal orientations.

8. The strapping system of claim 6, further comprising a strapping head actuator supported by the frame, the strapping head actuator operatively connected between the frame and the strapping head for effecting tilting movement of the strapping head.

9. A strapping system comprising a strapping chute for advancing an associated strapping material around and object to be strapped, and a strapping head, the strapping chute and the strapping head being supported by a frame mountable to an end effector, wherein the strapping head is pivotally secured to the frame for tilting movement relative to the chute.

10. The strapping system of claim 9, wherein the strapping head is pivotally secured to the frame.

11. The strapping system of claim 10, wherein the strapping chute includes a vertical track section mounted to the frame, and wherein the strapping head is pivotable about a non-vertical axis such that the strapping head can be tilted relative to the vertical track section.

12. The strapping system of claim 11, further comprising a strapping head actuator supported by the frame, the strapping head actuator operatively connected between the frame and the strapping head for effecting tilting movement of the strapping head.

13. A method of strapping an object comprising: positioning a strapping system adjacent the object, the strapping system having a frame, a strapping head mounted to the frame, a fixed vertical track section mounted to the frame, a lower track section mounted to the frame below the strapping head, an upper track section mounted to the frame above the strapping head, a movable track section mounted to a distal end of one of the upper or lower track sections, the movable track section movable from a first open position to a second closed position, the movable track section cooperating with the lower track section, the upper track section and the vertical track section when in the second closed position to form a chute for advancing strapping around the at least one associated object;advancing the upper and lower track sections into position on opposing sides of the object with the movable track section in the first open position;moving the movable track section to the second closed position;advancing strapping material through the chute to surround the object;tensioning the strapping material with the strapping head; andsevering the strapping material with the strapping head.