Material or article handling – Apparatus for positioning plural orderly articles onto pallet
Reexamination Certificate
1998-09-18
2001-07-10
Hess, Douglas (Department: 2167)
Material or article handling
Apparatus for positioning plural orderly articles onto pallet
C414S802000, C414S922000
Reexamination Certificate
active
06257826
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for the arranging of packages into a desired layout for palletization and shipment. Programmable package handlers allow the layout of each layer of a palletized stack to be defined differently.
BACKGROUND OF THE INVENTION
The secondary packaging of articles into packages appropriately sized for use by consumers has become an important phase of the manufacturing of many products. Shipment of these consumer packages, however, has created problems in shipping to retailers. Specifically, the small consumer packages have necessitated another step of packaging associated with shipment comprising assembling the consumer packages into layers to be stacked.
One specific example of the primary and seconding packaging of articles and assembly of pallet layers for shipment is found in the distribution of beverages, which are primarily packaged in cans or bottles, then secondarily packaged into consumer multi-packs of various sizes, most frequently six, twelve or twenty-four packs of cans or bottles. The multi-packs are arranged into layers and stacked onto a pallet for shipment from the manufacturer/bottler to the distributer or retailer. The secondary packaging of multi-packs in paperboard, cardboard, film or some combination of cardboard and film is followed by assembly of a number of multi-packs into a layer to be stacked onto a pallet. The assembled layer is then stacked onto the pallet by a palletizer.
Prior art devices and methods for assembling packages into layers for stacking onto a pallet include means for arranging the packages into layers in which the packages are uniformly oriented. However, a disadvantage of such uniform orientation is that, as each layer is stacked on top of the preceding layer, what is essentially created is a number of vertical stacks of the packages. That is, because each layer is identically arranged, vertical columns are the result of each package of a layer being placed squarely on the similarly positioned package of the preceding layer.
As the flexibility of packaging machines has increased, and the number of consumer packages of different sizes has increased, one trend has been the development of smaller consumer packages. The stacking and palletization of the smaller consumer packages has become problematic, however, because the vertical columns of packages created by the stacking of uniform layers have become more unstable. To stabilize the vertical columns of the palletized stacks, prior art stacking techniques and devices have included the use of intermediate layers of cardboard or packing material between layers and, in many instances, the use of film around the palletized stacks.
Typically the packages being assembled into layers and stacked on a pallet are not square, but rather are rectangular and have one side longer than the other. This difference is important and can be advantageous in improving the stability of the palletized stacks. By alternating the orientation of the packages, and assembling individual layers of the palletized stacks differently, the placement of packages onto packages of the preceding layer can be offset so that unstable vertical columns of packages are not created. Rather, the offset of the packages on successive layers allows interlocking to stabilize the palletized stack, thereby reducing or eliminating the need for additional support or stabilizing material such as intermediate layers of cardboard, paperboard, or use of film.
One prior art attempt to solve the problem of the instability of vertical columns by altering the layout of layers of the palletized stack is embodied in U.S. Pat. No. 5,320,478 to Gonsowski, et. al. The apparatus disclosed therein recognized the problem of instability of stacking small items on a pallet and solved the problem by alternately turning packages to vary the layout of successive layers of the stack. In the '478 Gonsowski apparatus a fixed turning mechanism is provided which turns and reorients packages that have been directed toward the turning mechanism by a laning mechanism.
The prior art solutions, including the '478 Gonsowski patent, have failed to provide a flexible means for assembling the packages into layers of various layouts in forming the palletized stack. An apparatus and method by which each layer of a palletized stack may be defined differently is advantageous because it increases the interlocking between layers and thereby, improves the stability of the palletized stack. An apparatus having a programmable package handler which receives each package individually and places and orients the package appropriately to provide a desired layout comprises such a solution and is advantageous over the prior art.
There is thus identified a need for a flexible apparatus and method allowing the assembly of packages into desirable and variable layouts for successive layers of a palletized stack. Alternating the layout of successive layers in this way is beneficial because the stability of the palletized stack is improved.
OBJECTS OF THE INVENTIONS
Accordingly it is an object of the present invention to provide an apparatus for receiving packages from a packaging machine and assembling them into a desired layout prior to stacking onto a pallet for shipment.
It is also an object of the present invention to provide a method for receiving packages from a packaging machine and assembling them into a desired layout prior to stacking onto a pallet for shipment.
It is an object of the present invention to provide a method for receiving packages from a packaging machine, positioning and orienting them onto a pre-palletization conveyor and, thereby, assembling the packages into a desired layout to be stacked onto a pallet for shipment.
Another object of the present invention is to provide a package handling apparatus wherein an operator defines the layout of packages assembled into a layer of a palletized stack through simple graphic arrangement on a computer screen.
Yet another object of the present invention is to provide an apparatus for assembling packages into a desired arrangement utilizing package handlers that are controlled by a programmable logic controller.
A further object of the present invention is to provide a programmable package-handling apparatus that is programmed to change the layout of each layer of a palletized stack to avoid repetition and thereby improve the stability of the palletized stack.
Yet another object of the present invention is to provide a package handling apparatus having handlers that can receive a variety of different sized packages and can grip, position and orient the packages onto a pre-palletization conveyor to create a desired layout.
Another object of the present invention is to provide an apparatus for receiving packages from a packaging machine, positioning and orienting the packages on a pre-palletization conveyer to create a desired layout, collecting the packages at a collection station, and compressing the packages into tight face-to-face engagement just prior to stacking the layer onto the pallet.
Yet another object of the present invention is to provide an apparatus for receiving packages from a packaging machine and assembling them into a desired layout for stacking onto a pallet which does not require lane dividers.
Another object of the present invention is to provide a method for handling and assembling packages into a user defined layout comprising the steps of receiving packages from a packaging machine, positioning and orienting the packages onto a pre-palletization conveyor to create a desired layout, collecting the packages at a collection station, and compressing the packages into the desired layout prior to placement on the palletized stack.
These and other objects of the present invention are satisfied by the preferred embodiment of the invention described in more detail herein. These objects are meant to be illustrative and not limiting. The manner of operation, novel features and further objects and advantages of this invention may be
Marti Jean
Neagle Claud Andrew
Hess Douglas
Kisters Kayat, Inc.
Macke R. Christian
LandOfFree
Package handling apparatus and method does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Package handling apparatus and method, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Package handling apparatus and method will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2451820