BACKGROUND
In a case erecting and sealing machine, a tape head applies tape to an erected case (e.g., cardboard box) to seal the top and/or bottom of the case. In an example, cases begin in a folded-flat configuration, are erected, the bottom is sealed, the case is packed with product, the top flaps closed and then sealed with tape. The process may include a conveyor that moves the case through a plurality of stations wherein case erection, product packing and case sealing are performed.
Known tape heads tension a spring in response to contact of a leading roller of the tape head with a leading side of an on-coming case that is propelled by a conveyor. Initial contact between the leading roller and the case presses tape against a leading side of the case. Continued contact between the leading roller and a trailing roller presses tape against the closed flaps of the case, thereby closing the case. The tension in the spring is used to move the trailing roller against and end of the tape to be secured to the trailing side of the case. Thus, a piece of tape joins the closed flaps of the case, and also extends onto the sides of the case.
A problem with such tape heads is that contact with the leading roller, sufficient to tension the spring, may deform the case. Such deformation is particularly likely if the case is not fully packed with ridged product. However, such tensioning is required by such systems to propel the trailing roller against the trailing side of the case, to thereby secure the end of the tape, after it has wrapped over the trailing side of the case.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to reference like features and components. Moreover, the figures are intended to illustrate general concepts, and not to indicate required and/or necessary elements.
FIG. 1 is an isometric view of a tape head having the roll of tape removed for clarity.
FIG. 2 is a side orthographic view of an example tape head in a state wherein a leading side of a case, moving right to left, has moved into contact with a leading roller.
FIG. 3 is a side orthographic view of an example tape head in a state wherein the leading roller has pressed tape onto the leading side of the case and is almost ready to transition from pressing against the leading side of the case to pressing against the top of the case.
FIG. 4 is a side orthographic view of an example tape head in a state wherein the leading roller is beginning to press tape against the adjacent flaps of the top of the case. The trailing roller has been raised to an elevation of the leading roller and will begin to press tape against the top flaps of the case when the case has advanced sufficiently.
FIG. 5 is a side orthographic view of an example tape head in a state wherein the trailing roller is pressing tape against the top of the case and the case has moved beyond contact with the leading roller.
FIG. 6 is a side orthographic view of an example tape head in a state wherein the knife blade mount arm has pivoted to a location at which it will cut the tape. The trailing roller has pressed the length of tape joining the flaps on the top of the case and is about to press tape against a trailing side of the case.
FIG. 7 is a side orthographic view of an example tape head in a state wherein the trailing roller is positioned to press tape against the trailing side of the case, as the case continues to move to the left.
FIG. 8 is a side orthographic view of an example tape head in a state wherein the trailing roller presses an end of a piece of tape against the trailing side of the case.
FIG. 9 is a flow diagram showing an example of the operation of a tape head for sealing cases.
DETAILED DESCRIPTION
Overview
The disclosure describes techniques for tape head structure and operation. In one context, a tape head is configured for use with case erection machinery that opens, assembles, fills and seals cases (e.g., cardboard boxes). Such cases may originally be configured in a stack of folded cases. At a first location along a conveyor, case erection machinery may grasp a case and open it from a folded-flat configuration into a three dimensional form. At a second location along the conveyor, a tape head may seal the flaps that form the bottom of the case. Farther along the conveyor, the case erector may then fill the case with product (e.g., retail-packaged goods). At a still farther location, the tape head may seal the flaps on the top of the case.
An example illustrating some of the tape head structure and operational techniques discussed herein—not to be considered a full or comprehensive discussion—may assist the reader. In the example, a tape head utilizes one or more actuators to drive the leading and trailing rollers, one or more tape guides, and a tape-cutting knife. In some examples, the actuators may be air-powered cylinders (i.e., air cylinders powered by compressed air and/or partial vacuum). However, solenoids, hydraulics, motors and/or other devices may be used as actuators.
In the example, a first air-powered cylinder may drive leading and trailing rollers and a second air-powered cylinder may drive a tape-cutting knife. The leading and trailing rollers may be mechanically linked, so that the first air-powered cylinder drives both rollers as the case approaches the rollers, contacts the rollers and then passes the rollers. (Alternatively, the leading and trailing rollers may each be driven by a separate actuator.) The first air-powered cylinder moves the rollers so that the leading roller presses tape to a leading (typically vertical) side of the advancing case. As the case advances on the conveyor, the first air-powered cylinder moves the rollers so that the leading roller presses tape against adjacent closed flaps on the top (i.e., typically horizontal side) of the case. As the case advances farther, the trailing roller also contacts the tape and presses it against the closed flaps. And as the case advances still farther to positions beyond contact with the leading roller, the first air-powered cylinder moves the rollers so that the trailing roller presses tape against a trailing (typically vertical) side of the advancing case.
Also in the example, a second air-powered cylinder may extend a tape-cutting knife to cut the tape. While the timing depends on the dimensions of the case being taped, the second air-powered cylinder may advance the knife after the case has advanced past the leading roller, but is still in contact with the trailing roller. After the tape has been cut, the knife may be retracted.
Example System and Techniques
FIG. 1 shows an example tape head 100 usable with machinery, such as case erection machinery, wherein tape is used to seal flaps of a case. In the example shown, a case may move in direction 102 with respect to the tape head. A tape roll mandrel 104 is supported by a tape roll support arm 106. The mandrel 104 and support arm 106 support a roll of adhesive tape that may be used to seal the flaps of a case.
A leading roller 108 makes initial contact with a case advancing in direction 102. In operation, the leading roller 108 presses a first end of a segment of tape against the leading side of a case as the case advances on a conveyor. The leading roller rolls up the side of the case as it advances, pressing tape against the vertical leading side of the case. The leading roller 108 then presses tape against the top of the case, sealing together two adjacent edges of two adjacent flaps.
The trailing roller 110 initially makes contact with the case after the leading roller 108 has pressed tape against the top of the case. The trailing roller 110 presses the tape against the adjacent flaps on top side of the case, in a manner similar to actions already performed by the leading roller 108. The trailing roller 110 then rolls down the trailing (typically vertical) side of the case as it advances, pressing tape against the vertical trailing side of the case. Accordingly, the leading and trailing rollers press the tape against the flaps on the top of the case, while the leading roller 108 presses tape against the leading side of the case and the trailing roller 110 presses tape against the trailing side of the case.
The leading roller 108 and trailing roller 110 may move in a related manner as a result of interconnected roller support arms, brackets, linkages and/or other means. For example, first and second support arms, supporting the leading and trailing rollers, respectively, may be moved by an air-powered cylinder or other actuator in accordance with one or more connecting linkages. Such interconnection(s) allow both rollers to be driven by one roller-controlling air cylinder 112. The roller-controlling air cylinder 112 may be configured so that air fittings at each end allow the piston to be pushed in both directions. Accordingly, the leading and trailing rollers may be lowered to a position wherein they contact the sides of the advancing case, and raised to a position wherein they contact the top of the case. Accordingly, the roller-controlling air cylinder 112 and/or linkage move the leading and trailing rollers 108, 110 about their respective pivots, in unison and/or simultaneously.
The roller-controlling air cylinder 112 may be supported at one end by a rod end 114 or pivot. The cylinder 112 may be supported at the other end by a mounting bracket 116. Thus, the roller-controlling air cylinder 112 may move somewhat, as the piston is pushed to different locations within the cylinder by application of compressed air to one or the other of the two ends, and as the rollers 108, 110 are moved into extended and retracted positions.
A pivoting support arm 118 for a tape-cutting knife is configured to pivot between a retracted position wherein the tape is not cut, and an extended position wherein the tape is cut. The pivoting support arm 118 is moved between the retracted and extended positions by a knife-controlling air cylinder 120. Air pressure alternately applied to opposite ends of the cylinder 120 allow the location of a knife to be precisely controlled with respect to time and/or a location of one or more cases on a conveyor line. In the example shown, one end of the knife-controlling air cylinder 120 may be attached to a fixed location 126 and the other end (rod end 122) may be attached to the pivoting support arm 118 at pivot 124.
The roller-controlling air cylinder 112 and the knife-controlling air cylinder 120 are configured to allow compressed air to be introduced, in an alternating, sensor-controlled and/or program-controlled manner, to each end of the respective air-powered cylinder. The compressed air moves a piston (in a direction based on which end of the cylinder is receiving compressed air) within each cylinder to a position to locate the rollers or knife in an appropriate location based on time, a location of a case, or other factor.
FIGS. 2 through 7 show an example tape head in a sequential series of views as a case moves from the right to the left. Accordingly, the structure and operation of different components is shown.
FIG. 2 shows the example tape head 100 in a state of initial contact 200 wherein a leading side 204 of a case 202, moving right to left, into contact with a leading roller 108 and a tape guide 206. The leading roller 108 is lowered to press tape against the leading side 204 of the case 202. As the case 202 moves to the left, the tape guide 206 positions tape (tape not shown for clarity) adjacent to, and the leading roller 108 presses the tape against, the leading side 204 of the case 202. In examples wherein the trailing roller 110 is linked to the leading roller 108 for movement in response to a single actuator, the trailing roller is also lowered. The pivoting support arm 118 for the knife may be in an extended or lowered position at this stage; however, it will be retracted or raised before the case 202 arrives at its location, to thereby avoid contact with the case. A support arm 208 supports the trailing roller 110 and is configured for rotation about pivot 210. A bracket 212, connected to the support arm 208, also rotates at pivot 210. The bracket 212 is driven by the rod end 114 of the roller-controlling air cylinder 112, and drives a linking rod 214. The linking rod 214 is links to, and drives, a support arm 216 carrying the leading roller 108. The support arm 216 rotates about pivot 218, to thereby provide a range of movement to the leading roller that is consistent with pressing tape against the leading side 204 and the top of the case 202.
FIG. 3 shows an example tape head 100 in a state 300 wherein the leading roller 108 has pressed tape onto the leading side 204 of the case 202 and is almost ready to wrap around the corner of the case to press tape against the adjacent flaps of the top 302 of the case. The support arm 216 of the leading roller 108 has rotated about a pivot 218 in response to contact with the leading side 204 of case 202. Accordingly, the leading roller 108 has moved both to the left and upwardly in the view shown (as compared to FIG. 2), to thereby maintain contact with tape to be pressed against the leading side 204 of the case 202.
FIG. 4 shows an example tape head 100 in a state 400 wherein the leading roller 108 has wrapped around the corner of the case 202 and is beginning to press tape against the adjacent flaps of the top 302 of the case. The trailing roller 110 has been raised to an elevation of the leading roller 108 and will begin to press tape against the top flaps of the case when the case 202 has advanced sufficiently. The knife-controlling air cylinder 120 has moved the pivoting support arm for the knife 118 into a position above the case 202, to thereby allow the case to pass under the knife.
FIG. 5 shows an example tape head 100 in a state 500 wherein the leading roller 108 is no longer in contact with the case 202 and the trailing roller 110 currently pressing tape against the top 302 of the case 202.
FIG. 6 shows an example tape head 100 in a state 600 wherein the knife blade mount arm 118 has pivoted in response to action by knife-controlling air cylinder 120 to a location at which it will cut the tape. The trailing roller 110, attached to support arm 208 and moving about pivot 210, has pressed the length of tape to join the flaps on the top 302 of the case 202 and is about to go around the top case corner and press tape against a trailing side 602 of the case 202.
FIG. 7 shows an example tape head 100 in a state 700 wherein the trailing roller 110 is positioned to press tape against the trailing side 602 of the case 202. As the case continues to move to the left, the support arm 208 of the trailing roller 110 will rotate about pivot 210 and keep the trailing roller in contact with the tape to be pressed against the trailing side 602 of case 202. The knife-controlling air cylinder 120 has positioned the pivoting support arm 118 of the knife into a position wherein the tape (not shown) was contacted by the knife, and has been cut. The tape guide 206 has rotated into a position that will assist in guiding an end of the tape not attached to the case 202 into a position wherein the roller 108 presses the tape into contact with a second case (not shown) that is moving into position on the conveyor belt (not shown).
FIG. 8 shows an example tape head 100 in a state 800 wherein the trailing roller 110 is pressing an end of a piece of tape against the trailing side 602 of the case 202. The leading roller 108 is in position to press tape against a leading side of a case that has not yet arrived. The tape guide 206 is in position to guide tape to the leading side of the case that will soon arrive.
Example Methods
FIG. 9 is a flow chart showing an example method 900 to operate a case sealer. The methods and operation may be performed and/or directed by any desired integrated circuit, logic devices, programming, etc. The example methods of FIG. 9 may be implemented at least in part using the techniques of FIGS. 1-8. However, the methods of FIG. 9 contain general applicability, and are not limited by other drawing figures and/or prior discussion. The functional blocks of FIG. 9 may be implemented by software and/or hardware structures or devices that are configured to operate a case sealer and/or tape head device. In one example, one or more functional blocks may be implemented by techniques and devices including a microprocessor, a controller, a microcontroller, a ladder logic device, or other general- or specific-purpose logic or control device, etc. Additionally or alternatively, one or more memory devices, computer-readable media, application specific integrated circuits (ASIC), software blocks, subroutines, programs, etc., may also be utilized. Computer-readable media, as the term is used herein, includes, at least, two types of computer-readable media, namely computer storage media and communications media. Computer storage media includes volatile and non-volatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules, or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other non-transmission medium that can be used to store information for access by a computing device. Computer storage media may be non-transitory in nature. In contrast, communication media may embody computer readable instructions, data structures, program modules, or other data in a modulated data signal, such as a carrier wave, or other transmission mechanism. As defined herein, computer storage media does not include communications media.
FIG. 9 is a flow diagram showing an example processes 900 which are representative of techniques for use in case sealing. The processes may, but need not necessarily, be implemented in whole or in part by the microprocessor 902 and/or the memory 904. Microprocessor 902 and/or memory 904 may be part of a case erector machine and/or part of the tape head of such a machine. The microprocessor 902 and the memory 904 and associated programming may control actuators (e.g., compressed air-powered cylinders) that in turn move other mechanical parts. Actual control may be based solenoid controlled valves, electrically controlled motors, etc. Accordingly, programming may be stored in memory 904 and executed by the processor 902 to control and operate actuators, motors, valves, compressed air-driven cylinders, etc., to thereby operate the tape head 100 and/or associated machinery.
At operation 906, a leading roller is positioned to contact a leading edge of an advancing case. In the example of FIG. 2, the leading roller 108 is fully lowered, such as by operation of an air-powered cylinder (e.g., 112 of FIG. 1) or other actuator. The example shows that the case has advanced (such as by movement on a conveyor, not shown) to a point wherein the leading side 204 of the case 202 has just contacted the leading roller 108.
At operation 908, the leading roller presses a first end of a piece of tape against a leading side of the case. In the example of FIG. 3, the leading roller 108 moves upwardly as it presses the tape against the leading side 204 of the case 202.
At operation 910, the leading roller moves around the corner, from the vertical leading side to a horizontal top of the case, to press the tape against adjacent flaps of the top of the case. In the example of FIG. 4, the leading roller 108 has been elevated to press the tape against the adjacent flaps on the top 302 of the case 202 to thereby seal those flaps together.
At operation 912, a trailing roller, in a manner similar to the leading roller before it, presses the tape against the adjacent flaps on the top of the case as the advancing case moves below it. In the example of FIG. 5, the case 202 has moved past the leading roller; however, the trailing roller 110 continues to press the tape against the adjacent flaps of the top 302 of the case 202.
At operation 914, a knife, optionally carried by a pivoting support arm, is lowered into position to cut the tape. As seen in the example of FIG. 6, the knife and arm 118 may be moved by operation of an air-powered cylinder 120 or other actuator.
At operation 916, a tape guide is extended into a position that will guide an end of the tape created by the cut at operation 914 so that it contact a case that is moving toward the tape head. As seen in the example of FIG. 7, the tape guide 206 is lowered into position, wherein it will guide an end of the tape on the mandrel 104 into contact with a leading side of an advancing case.
At operation 918, a second end of a piece of tape (the second of the tape segment having the first end discussed at operation 908) is pressed against a trailing side of the case. In the example of FIG. 8, the trailing roller 110 rotates about a pivot 210 to press the tape against, and adhere it to, the trailing side 602 of the case 202.
Conclusion
Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as exemplary forms of implementing the claims.
Patent Application
20170015453
