Granted Patent B2

US 12,473,111 · App. 17/186,618 · Granted Nov 18, 2025

Inventors: H. J. Paul Langen (Brampton, CA); Sharran Badrie (Brampton, CA); Tomasz Kardynal (Mississauga, CA); Constantin Mighiu (Thornhill, CA)

Assignee: AFA SYSTEMS LTD.

B65B35/30B65B5/06B65B7/20B65B43/10B65B43/126B65B43/54

Abstract

Claims (161)

1 . A system for bottom loading an open case through a downward facing opening in said open case, with a plurality of un-cased items, wherein each of said plurality of un-cased items comprises a separate, rigid or semi-rigid upstanding body being self-supported on a base portion, the system comprising:

an item delivery apparatus operable to deliver said plurality of un-cased items to a transfer station;

a collation platform operable to support said plurality of un-cased items;

a pedestal apparatus operable to support the plurality of items;

a first transfer apparatus operable to transfer said plurality of un-cased items at said transfer station from said item delivery apparatus to said collation platform, to form a group of un-cased items on said collation platform from said plurality of un-cased items;

a second transfer apparatus operable to transfer the group of un-cased items from said collation platform to said pedestal apparatus;

at least one transversely extending movement rod operable to be driven in longitudinal movement by a rod movement drive apparatus;

a case movement apparatus located proximate said pedestal apparatus, said case movement apparatus operable to move said open case in a path that sheaths the group of un-cased items located on said pedestal apparatus with said open case;

wherein in operation:

(a) said item delivery apparatus delivers said plurality of un-cased items to said transfer station;

(b) said first transfer apparatus transfers said plurality of un-cased items from said item delivery apparatus to said collation platform, to form said group of un-cased items on said collation platform;

(c) said second transfer apparatus transfers said group of un-cased items from said collation platform to a first upstream surface of said pedestal apparatus;

(d) said at least one movement rod engages said group of un-cased items at a rearward transverse side of said group of un-cased when said group of un-cased items is located on said first upstream surface of said pedestal apparatus and moves said group of un-cased items on said pedestal apparatus onto a second downstream surface of said pedestal apparatus;

(e) said at least one movement rod dis-engages from said group of un-cased items on said second downstream surface of said pedestal apparatus;

(f) after (e) said case movement apparatus moves said open case to sheath said group of un-cased items located on said pedestal apparatus such that said group of un-cased items are received through said downward facing opening into said open case and a side of said open case is received between said at least one rod and said rearward side of said group of un-cased items, whereby said un-cased group of items is formed into a group of cased items;

(g) after (f) said at least one rod re-engages said open case at a rearward side of said open case on said pedestal apparatus, and moves said open case and said group of cased items held therein to a location for further processing.

2 . The system as claimed in claim 1 wherein said at least one movement rod comprises first and second movement rods and wherein in operation said first movement rod is a trailing movement rod that engages said rearward transverse side of said group of un-cased items and said second movement rod is a leading movement rod that engages a forward transverse side of said group of un-cased items and wherein said trailing and leading movement rods move in tandem contact with said group of un-cased items to move said group of un-cased items on at least one support surface of said pedestal apparatus.

3 . The system as claimed in claim 1 , wherein said case movement apparatus comprises a multi-axis robot arm having an end effector operable to engage with, and release, said open case.

4 . The system as claimed in claim 3 , wherein said end effector is mounted to a multi-segment arm of said robot arm and said end effector is operable to rotate about several axes of rotation provided by said multi-segment arm.

5 . The system as claimed in claim 3 , wherein said end effector is operable to rotate about at least six separate axes of rotation.

6 . The system as claimed in claim 3 , wherein said end effector is operable to engage a flattened case blank and open said flattened case blank into said open case that is suitably configured to sheath said group of un-cased items.

7 . The system as claimed in claim 3 , wherein said items are each supported on a base portion in a generally vertically upright orientation, and wherein end effector is operable to move said open case in a path to sheath said group of un-cased items, said open case having a tilted position in which while said open case is located proximate to said group of un-cased items, said open case is tilted from a vertical axis at a tilt angle.

8 . The system as claimed in claim 7 , wherein in said tilted position, of the said open case is tilted from a vertical axis by said tilt angle being in the range of 5 to 20 degrees from the vertical axis.

9 . The system as claimed in claim 8 wherein said tilt angle comprises both a transverse tilt angle and a longitudinal tilt angle each in the range of 5 to 20 degrees from the vertical axis.

10 . The system as claimed in claim 7 wherein end effector is operable to move said open case from said tilted position by pivoting said open case about a first bottom corner of said open case such that a diagonally opposite corner of said open case moves in an arced path portion, to a case engagement position.

11 . The system as claimed in claim 10 wherein when in operation, said end effector moves said open case in said arced path portion, to said case engagement position, a bottom plane defined by bottom edges of a plurality of bottom flaps of said open case, will become parallel to a horizontal plane defined by a top surface plane of the group of un-cased items.

12 . The system as claimed in claim 10 , wherein said path of said end effector has a vertical path portion such that robotic arm is operable to move said open case vertically downward from said case engagement position to a fully loaded position.

13 . The system as claimed in claim 7 , wherein said open case has a plurality of bottom flaps, and when said open case is angled at said tilt angle, a first side flap is positioned below a top surface of said group of un-cased items.

14 . The system as claimed in claim 13 and when said open case is angled at said tilt angle, a second side flap of said open case, opposite to said first side flap, is also positioned below said top surface of said group of un-cased items.

15 . The system as claimed in claim 7 , wherein said path of said end effector has a vertical path portion and wherein while said group of un-cased items is on said pedestal apparatus, said end effector changes the tilt angle to zero as said open case moves from said tilted position to said vertical path portion.

16 . The system as claimed in claim 15 wherein during said vertical path portion, said open case is moved vertically downward to locate said group of un-cased items within a storage space of said open case.

17 . The system as claimed in claim 1 , wherein the first transfer apparatus comprises a header configured to actuate from a first position to a second position, wherein the first position of the header allows for a collated row of individual items to move in front of the header, and wherein in the second position of the header pushes said plurality of items from the input delivery apparatus to the collation platform.

18 . The system as claimed in claim 17 wherein said first transfer apparatus further comprises a topple plate configured to move in co-ordinated movement with said header, said topple plate operable to assist in maintaining said plurality of items in an upright orientation during movement from said input delivery apparatus to said collation platform.

19 . The system as claimed in claim 18 , wherein the second transfer apparatus comprises a transfer paddle operable to slide said group of un-cased items from a support surface of said collation platform onto said central loading platform of said pedestal apparatus.

20 . The system as claimed in claim 1 , wherein the second transfer apparatus comprises a transfer paddle operable to move said group of un-cased items from said collation platform to said pedestal apparatus.

21 . The system as claimed in claim 1 , further comprising transversely spaced, opposed guide members positioned to support opposed longitudinal sides of said plurality of items when said plurality of items are being transferred by said first transfer to said collation platform, to form said group of un-cased items on said collation platform.

22 . The system as claimed in claim 1 , further comprising transversely spaced, opposed guide members positioned to support opposed longitudinal sides of said group of un-cased items when said group of un-cased items are being transferred by said second transfer apparatus from said collation platform to said pedestal apparatus.

23 . The system as claimed in claim 1 further comprising an output conveyor configured to receive the open case from the pedestal apparatus.

24 . The system as claimed in claim 1 wherein the plurality of un-cased items are bottles.

25 . A system of loading an open case with a plurality of un-cased items, the system comprising:

an item delivery apparatus operable to deliver said plurality of un-cased items to a transfer station;

a collation platform operable to support said plurality of un-cased items;

a pedestal apparatus operable to support the group of un-cased items;

a first transfer apparatus operable to transfer said plurality of un-cased items from said item delivery apparatus at said transfer station, to said collation platform, to form a group of un-cased items on said collation platform;

a second transfer apparatus operable to transfer the group of un-cased items from said collation platform to said pedestal apparatus;

at least one movement rod operable to be driven in longitudinal movement by a rod movement drive apparatus;

a case movement apparatus located proximate said pedestal apparatus, said case movement apparatus operable to move an open case in a path that sheaths a group of items located on said pedestal apparatus with an open case;

wherein in operation:

(a) said item delivery apparatus delivers said plurality of un-cased items to said transfer station;

(b) said first transfer apparatus transfers said plurality of un-cased items from said item delivery apparatus at said transfer station, to said collation platform, to form said group of un-cased items on said collation platform;

(c) said second transfer apparatus transfers said group of un-cased items from said collation platform to said pedestal apparatus;

(d) said at least one movement rod engages said group of un-cased items and moves said group of un-cased items while on said pedestal apparatus;

(e) said at least one movement rod dis-engages from said group of un-cased items on said pedestal apparatus;

(f) said case movement apparatus moves an open case to sheath and encase said group of items located on said pedestal apparatus;

wherein said at least one movement rod comprises first and second movement rods and wherein in operation said first movement rod is a trailing movement rod that engages a rearward side of said group of un-cased items and said second movement rod is a leading movement rod that engages a forward side of said group of un-cased items, and wherein said trailing rod and leading rod move in tandem contact with said group of un-cased items to move said group of un-cased items on said pedestal apparatus.

26 . The system as claimed in claim 25 , wherein the pedestal apparatus further comprises: a first folding platform; a second folding platform; and a central loading platform located between said first folding platform and said second loading platform; and wherein in operation, after (f), then (g) wherein said first and second movement rods re-engage said group of cased items on said central loading platform, and move said open case and said group of cased items held therein, in forward and rearward movements over said first folding platform, said central loading platform and second folding platform to thereby close a trailing bottom flap and a leading bottom flap of said open case, to support positions between said group of cased items and said pedestal apparatus.

27 . The system as claimed in claim 26 , wherein the first folding platform and the second folding platform are located on opposite longitudinal sides of the central loading platform.

28 . The system as claimed in claim 27 wherein each of said first folding platform and said second folding platform, comprise a first surface that is a ramp portion at a proximal side to the central loading platform and a second surface that is a flat portion at a distal side of the central loading platform.

29 . The system as claimed in claim 26 , wherein said system is operable such that after (g), then (h) wherein said first and second movement rods move said open case to a flap folding apparatus, said flap folding apparatus is operable to close first and second opposed bottom side flaps of said open case.

30 . The system as claimed in claim 29 wherein said open case has a plurality of top flaps and said flap folding apparatus is operable to close said plurality of top flaps of said open case.

31 . The system as claimed in claim 29 , wherein said system further comprises a flap sealing apparatus operable to seal the top flaps and bottom flaps of said open case.

32 . The system as claimed in claim 26 , further comprising a gate apparatus operable for movement between (i) a closed position wherein said trailing movement rod is positioned beneath said at least one support surface of said pedestal apparatus and an opening in said at least one support surface of said pedestal apparatus is closed by said gate such that said group of un-cased items can pass from said collation platform, over said gate and onto said pedestal apparatus; and (ii) an open position which allows said trailing movement rod to move through said opening in said at least one support surface of said pedestal apparatus to an engagement position behind said group of un-cased items on said pedestal apparatus.

33 . The system as claimed in claim 25 wherein said first and second movement rods are generally oriented to and extend in a direction generally transverse direction and said first and second movement rods move forwards and backwards in a longitudinal direction of movement relative to said pedestal apparatus.

34 . The system as claimed in claim 25 , wherein said pedestal apparatus comprises:

a first folding platform;

a second folding platform; and

a central pedestal disposed longitudinally between said first folding platform and the second folding platform;

wherein, in operation, the first and second movement rods move tandem to move the open case and the group of items held therein, in forward and rearward movements over and relative to the first folding platform, the central pedestal and the second folding platform to thereby close a trailing bottom flap and a leading bottom flap of the open case.

35 . The system as claimed in claim 25 wherein the plurality of un-cased items are a plurality of un-cased bottles.

36 . A system for bottom loading an open case through a downward facing opening in said open case, with a plurality of items, wherein each of said plurality of items comprises a rigid or semi-rigid upstanding body being self-supported on a base portion, the system comprising:

an item delivery apparatus operable to deliver said plurality of items to a transfer station;

a collation platform operable to support said plurality of items;

a pedestal operable to support the plurality of items;

an item movement sub-system operable to:

move said plurality of items at the transfer station from the item delivery apparatus to the collation platform, to form a group of un-cased items on the collation platform; and

move the group of un-cased items from the collation platform to the pedestal;

a case movement apparatus located proximate to the pedestal apparatus, the case movement apparatus operable to move said open case in a path that sheaths, with said open case, said group of un-cased items located on the pedestal;

wherein, in operation:

the item delivery apparatus delivers the plurality of items to the transfer station;

the item movement sub-system moves the plurality of items from the item delivery apparatus to the collation platform, to form the group of un-cased items on the collation platform;

the item movement sub-system moves the group of un-cased items from the collation platform to the pedestal;

the case movement apparatus moves the open case to sheath the group of un-cased items located on the pedestal, such that said group of cased items are received through said downward facing opening in said open case to form a group of cased items;

wherein said system further comprises:

a first folding platform;

a second folding platform; wherein the first folding platform is located on a longitudinally opposite side of said pedestal to a side where said second folding platform is located;

wherein, in operation, the item movement sub-system provides forward and rearward longitudinal movements of the open case and the group of cased items held therein, relative to first, second and third upward facing surfaces of respectively the first folding platform, the pedestal and the second folding platform, to thereby close a trailing bottom flap and a leading bottom flap of the open case with the group of cased items held in said open case.

37 . The system as claimed in claim 36 wherein the item moving sub-system is further operable to hold the group of un-cased items on said pedestal and operable to release said group of un-cased items to enable said group of un-cased items located on said pedestal to be sheathed with said open case by said case movement apparatus.

38 . The system as claimed in claim 37 wherein said item moving sub-system comprises at least one movement rod operable to engage said group of un-cased items and move said group of items to said pedestal and wherein said at least one movement rod thereafter dis-engages from said group of un-cased items on said pedestal.

39 . The system as claimed in claim 36 wherein the plurality of items are bottles.

40 . A system for bottom loading an open case through a downward facing opening in said open case, with a plurality of items, wherein each of said plurality of items comprises a separate, rigid or semi-rigid upstanding body being self-supported on a base portion, the system comprising:

an item delivery apparatus operable to deliver said plurality of items to a transfer station;

a collation platform operable to support said plurality of items;

a pedestal apparatus operable to support the plurality of items;

a first transfer apparatus operable to transfer said plurality of items at said transfer station, from said item delivery apparatus to said collation platform, to form a group of items on said collation platform;

a second transfer apparatus operable to transfer the group of items from said collation platform to said pedestal apparatus;

at least one transversely extending movement rod operable to be driven in longitudinal movement by a rod movement drive apparatus;

a case movement apparatus located proximate said pedestal apparatus, said case movement apparatus operable to move said open case in a path that sheaths a group of items located on said pedestal apparatus with said open case;

wherein in operation:

a. said item delivery apparatus delivers said plurality of items to said transfer station;

b. said first transfer apparatus transfers said plurality of items from said item delivery apparatus to said collation platform, to form said group of items on said collation platform;

c. said second transfer apparatus transfers said group of items from said collation platform to a first upstream surface of said pedestal apparatus;

d. said at least one movement rod engages said group of items at a rearward transverse side of said group of products when said group of products is located on said first upstream surface of said pedestal apparatus and moves said group of items on said pedestal apparatus onto a second downstream surface of said pedestal apparatus;

e. said at least one movement rod dis-engages from said group of items on said second downstream surface of said pedestal apparatus;

f. after (e) said case movement apparatus moves said open case to sheath said group of items located on said pedestal apparatus such that said group of items are received through said downward facing opening in said open case;

and wherein said at least one movement rod comprises first and second movement rods, and wherein in operation said first movement rod is a trailing movement rod that engages a rearward side of said group of items and said second movement rod is a leading movement rod that engages a forward side of said group of items and wherein said trailing and leading movement rods move in tandem contact with said group of items to move said group of items from said first upstream surface of said pedestal apparatus onto said second downstream surface of said pedestal apparatus;

and wherein said system further comprises: a gate apparatus operable for movement between (i) a closed position wherein said trailing movement rod is positioned below the vertical level of the second downstream surface of said pedestal apparatus and an opening between said collation platform and said second downstream support surface of said pedestal apparatus is closed by said gate such that said group of items can pass from said collation platform, over a surface of said gate and onto said second downstream surface of said pedestal apparatus; and (ii) an open position which during operation, permits said trailing movement rod to move through said opening to an engagement position behind said group of items on said first upstream surface of said pedestal apparatus.

41 . The system as claimed in claim 40 , wherein said gate apparatus is positioned longitudinally downstream of said collation platform.

42 . The system as claimed in claim 40 , wherein the plurality of items comprises a plurality of bottles.

43 . A system for bottom loading an open case through a downward facing opening in said open case, with a plurality of items, wherein each of said plurality of items comprises a rigid or semi-rigid upstanding body being self-supported on a base portion, the system comprising:

an item delivery apparatus operable to deliver said plurality of items to a transfer station;

a collation platform operable to support said plurality of items;

a pedestal apparatus operable to support the plurality of items;

a first transfer apparatus operable to transfer said plurality of items at said transfer station, from said item delivery apparatus to said collation platform, to form a group of items on said collation platform;

a second transfer apparatus operable to transfer the group of items from said collation platform to said pedestal apparatus;

at least one transversely extending movement rod operable to be driven in longitudinal movement by a rod movement drive apparatus;

a plurality of transversely spaced, opposed guide members positioned to support opposed longitudinal sides of said group of items when said group of items are being transferred by said second transfer apparatus from said collation platform to said pedestal apparatus;

a case movement apparatus located proximate said pedestal apparatus, said case movement apparatus operable to move said open case in a path that sheaths a group of items located on said pedestal apparatus with said open case;

wherein in operation:

(a) said item delivery apparatus delivers said plurality of items to said transfer station;

(b) said first transfer apparatus transfers said plurality of items from said item delivery apparatus to said collation platform, to form said group of items on said collation platform;

(c) said second transfer apparatus transfers said group of items from said collation platform to a first upstream surface of said pedestal apparatus with the guide members supporting opposed longitudinal sides of said group of items

(d) said at least one movement rod engages said group of items at a rearward transverse side of said group of products when said group of products is located on said first upstream surface of said pedestal apparatus and moves said group of items on said pedestal apparatus onto a second downstream surface of said pedestal apparatus;

(e) said at least one movement rod dis-engages from said group of items on said second downstream surface of said pedestal apparatus;

(f) after (e) said case movement apparatus moves said open case to sheath said group of items located on said pedestal apparatus such that said group of items are received through said downward facing opening in said open case and a side of said open case is received between said at least one rod and said rearward side of said group of items, and opposed longitudinal sides of said case are received between respective longitudinal sides of said group of items and said guide members.

44 . The system as claimed in claim 43 , wherein the plurality of items comprises a plurality of bottles.

45 . A system for bottom loading an open case through a downward facing opening in said open case, with a plurality of items, wherein each of said plurality of items comprises a rigid or semi-rigid upstanding body being self-supported on a base portion, the system comprising:

an item delivery sub-system operable to deliver said plurality of items to a collation platform, said collation platform operable to support said plurality of items;

a pedestal apparatus located downstream of said collation platform and operable to support the plurality of items;

a transfer apparatus operable to transfer the group of items from said collation platform to said pedestal apparatus;

transversely oriented first and second movement rods operable to be driven in longitudinal movement by a rod movement drive apparatus; wherein in operation said first movement rod is a trailing movement rod that engages a rearward side of said group of items and said second movement rod is a leading movement rod that engages a forward side of said group of items and wherein said trailing and leading movement rods move in tandem contact with said group of items to move said group of items on at least one support surface of said pedestal apparatus;

a case movement apparatus located proximate said pedestal apparatus, said case movement apparatus operable to move said open case in a path that sheaths a group of items located on said pedestal apparatus with said open case;

wherein in operation:

(a) said item delivery apparatus delivers said plurality of items to said collation platform;

(b) said transfer apparatus transfers said plurality of items from said collation platform to said pedestal apparatus;

(c) said first and second movement rods engage said group of items and move said group of items on said pedestal apparatus;

(d) said first and second movement rods dis-engage from said group of items on said pedestal apparatus;

(e) said case movement apparatus moves said open case to sheath said group of items located on said pedestal apparatus such that said group of items are received through said downward facing opening in said open case;

and wherein said system further comprises: a gate apparatus operable for movement between (i) a closed position wherein said trailing movement rod is positioned beneath said at least one support surface of said pedestal apparatus and an opening in said at least one support surface of said pedestal apparatus is closed by said gate such that said group of items can be transferred by said transfer apparatus from said collation platform, over said gate and onto said pedestal apparatus; and (ii) an open position which allows said trailing movement rod to move through said opening in said at least one support surface of said pedestal apparatus to an engagement position behind said group of items on said pedestal apparatus.

46 . The system as claimed in claim 45 , wherein the pedestal apparatus further comprises: a first folding platform; a second folding platform; and a central loading platform located between said first folding platform and said second loading platform; and wherein in operation, after (e), then (f) wherein said first and second movement rods re-engage said group of items on said central loading platform, and provide for relative movement of said open case and said group of items held therein, in forward and rearward relative movements over said first folding platform, said central loading platform and second folding platform, to thereby close a trailing bottom flap and a leading bottom flap of said open case, to support positions between said group of items and said pedestal apparatus.

47 . The system as claimed in claim 46 , wherein the first folding platform and the second folding platform are located on opposite longitudinal sides of the central loading platform.

48 . The system as claimed in claim 47 , wherein each of said first folding platform and said second folding platform, comprise a first surface that is a ramp portion at a proximal side to the central loading platform and a second surface that is a flat portion at a distal side of the central loading platform.

49 . The system as claimed in claim 46 , wherein said system is operable such that after (f), then (g) wherein said first and second movement rods move said open case to a flap folding apparatus, said flap folding apparatus is operable to close first and second opposed bottom side flaps of said open case.

50 . The system as claimed in claim 49 wherein said open case has a plurality of top flaps and said flap folding apparatus is operable to close said plurality of top flaps of said open case.

51 . The system as claimed in claim 50 , wherein said system further comprises a flap sealing apparatus operable to seal the top flaps and bottom flaps of said open case.

52 . The system as claimed in claim 45 , wherein the plurality of items comprises a plurality of bottles.

53 . A system for loading cases with a plurality of items, the system comprising:

an item delivery apparatus operable to deliver the plurality of items to a transfer station;

a collation platform operable to support a group of items;

a pedestal apparatus operable to support the group of items;

an item movement sub-system operable to:

move the plurality of items at the transfer station, from the item delivery apparatus to the collation platform, to form the group of items on the collation platform; and

move the group of items from the collation platform to the pedestal apparatus;

wherein said pedestal apparatus comprises a central pedestal, a first folding platform and a second folding platform, wherein the first folding platform comprises a ramp portion at a proximal side to the central pedestal and a flat portion at a distal side of the central pedestal, and wherein the second folding platform comprises a ramp portion at a proximal side to the central pedestal and a flat portion at a distal side of the central pedestal;

a case movement and loading sub-system operable to move an open case blank to a position such that an open case blank is loaded with a group of items located on the central pedestal, the case movement and loading sub-system also operable to move the open case blank and the group of items held therein, in forward and rearward movements over the first folding platform, the central pedestal and the second folding platform to thereby close a trailing bottom flap and a leading bottom flap of the open case blank;

wherein, in operation:

the item delivery apparatus delivers a plurality of items to the transfer station;

the item movement sub-system transfers a plurality of items from the item delivery apparatus at the transfer station, to the collation platform, to form the group of items on the collation platform;

the item movement sub-system transfers the group of items from the collation platform to the central pedestal;

the case movement and loading sub-system loads the open case blank with the group of items located on the central pedestal; and

the case movement and loading sub-system moves the open case blank and the group of items held therein, in forward and rearward movements over the first folding platform, the central pedestal and the second folding platform to thereby close the trailing bottom flap and the leading bottom flap of the open case blank.

54 . The system as claimed in claim 53 , wherein the plurality of items comprises a plurality of bottles.

Assignments (1)

Priority Claims (1)

Continuity (1)

References Cited (274)