Programmable load forming system, components thereof, and methods of use
First Claim
1. A programmable load forming system, comprising:
- a robot comprising;
a moveable arm configured to carry at least one bundle; and
a robot controller;
a computer operably coupled to the robot controller, the computer programmed with instructions and operable to communicate the instructions to the robot controller, the instructions comprising;
downloading a calculated path from the computer to the robot controller, the calculated path defined, in part, by the stacking pattern;
moving at least one bundle along the calculated path to position the at least one bundle in a predetermined stacking position of a stacking pattern using the robot; and
determining if the robot has completed moving along the calculated path.
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Accused Products
Abstract
Programmable load forming systems, components thereof, and methods of use are disclosed. In one aspect, a programmable load forming system is programmed to perform the method of downloading a calculated path from the computer to the robot controller, moving one or more bundles along the calculated path to position the one or more bundles in a predetermined stacking position of a stacking pattern using the robot, and determining if the robot has completed moving along the calculated path. The calculated path is defined, in part, by the stacking pattern and other parameters such as, for example, bundle geometry, bundle levelness, bundle compressibility, among other parameters. In another aspect, the system is programmed to perform a method of sensing the top of a bundle and controllably placing a bundle. Additional aspects are directed to systems and methods of safely operating the robot and an inventive hopper design for holding bottom/tie sheets.
113 Citations
45 Claims
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1. A programmable load forming system, comprising:
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a robot comprising;
a moveable arm configured to carry at least one bundle; and
a robot controller;
a computer operably coupled to the robot controller, the computer programmed with instructions and operable to communicate the instructions to the robot controller, the instructions comprising;
downloading a calculated path from the computer to the robot controller, the calculated path defined, in part, by the stacking pattern;
moving at least one bundle along the calculated path to position the at least one bundle in a predetermined stacking position of a stacking pattern using the robot; and
determining if the robot has completed moving along the calculated path. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of stacking bundles in a stacking pattern using a programmable load forming system, comprising:
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downloading a calculated path from a computer to a robot controller of a robot, the calculated path defined, in part, by the stacking pattern;
moving at least one bundle along the calculated path to position the at least one bundle in a predetermined stacking position of the stacking pattern using the robot; and
determining if the robot has completed moving along the calculated path. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18)
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19. A programmable load forming system, comprising:
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a robot comprising;
a moveable arm configured to carry at least one bundle; and
a robot controller;
a computer readable medium containing instructions to cause the robot to perform a method comprising;
lowering the at least one bundle onto the lower bundle using a gripping mechanism of a robot;
allowing the gripping mechanism to move vertically a set distance responsive to the at least one bundle being lowered onto the lower bundle, upon the gripping mechanism moving the set distance the act of lowering the at least one bundle is stopped; and
moving the gripping mechanism having the at least one bundle retained thereon upwardly a predetermined distance. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26, 31)
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27. A method of placing at least one bundle on a lower bundle using a programmable load forming system, comprising:
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lowering the at least one bundle onto the lower bundle using a gripping mechanism of a robot;
allowing the gripping mechanism to move vertically a set distance responsive to the at least one bundle being lowered onto the lower bundle, upon the gripping mechanism moving the set distance the act of lowering the at least one bundle is stopped; and
moving the gripping mechanism having the at least one bundle retained thereon upwardly a predetermined distance. - View Dependent Claims (28, 29, 30, 32)
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33. A programmable load forming system, comprising:
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a robot comprising;
a moveable arm configured to carry at least one bundle; and
a robot controller;
computer readable medium containing instructions to cause the robot to perform a method comprising;
stopping the moveable arm from moving along a path that the robot was instructed to move along; and
moving the gripping mechanism from a first location to a reference location in which the gripping mechanism can be rotated without physical interference from a part of the programmable load forming system without an operator determining the path that the gripping mechanism moves along. - View Dependent Claims (34, 35, 36, 37, 38)
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39. A method of manipulating a moveable arm of a robot included in a programmable load forming system, comprising:
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stopping the moveable arm from moving along a path that the robot was instructed to move along; and
moving the gripping mechanism from a first location to a reference location in which the gripping mechanism can be rotated without physical interference from a part of the programmable load forming system without an operator determining the path that the gripping mechanism moves along. - View Dependent Claims (40, 41, 42)
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43. A hopper for holding tie/bottom sheets and configured for use in a programmable load forming system, the hopper positioned adjacent to a tie/bottom sheet build zone conveyor of the programmable load forming system, the hopper comprising:
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a shelf structure including a plurality of shelves spaced apart from each other, each of the shelves not being enclosed at one end to facilitate operator access thereto; and
a plurality of cantilevered arms, each of the shelves is associated with one of the cantilevered arms, each of the cantilevered arms including an arm positioned over one of the shelves, each of the arms carries a sheet retention device operable to lift a tie/bottom sheet so that a sheet arm of the programmable load forming system can transport the tie/bottom sheet to the tie/bottom sheet build zone conveyor. - View Dependent Claims (44, 45)
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Specification