Programmable load forming system, components thereof, and methods of use

• US 8,000,837 B2
• Filed: 09/28/2005
• Issued: 08/16/2011
• Est. Priority Date: 10/05/2004
• Status: Active Grant

• Current Assignee: Alliance Machine Systems International LLC (Barry-Wehmiller Group Incorporated)
• Original Assignee: J&L Group International, LLC
• Inventors: Holt, Andrew B., Brown, Kevin P., Allen, Robert M., Vershum, Lynn E.
• Primary Examiner(s): Trammell; James P
• Assistant Examiner(s): Marc; McDieunel
• Application Number:
  US11/239,665
• Publication Number:
  US 20060106487A1
• Time in Patent Office: 2,148 Days
• Field of Search: 700/245, 700/213, 700/247, 700/257, 414/788.9, 414/788.12, 414/791.6, 414/792.9, 83/86, 83/87, 83/94, 209/534, 219/74
• US Class Current: 700/245
• CPC Class Codes: B65G 61/00 Use of pick-up or transfer devices or of manipulators for stacking or de-stacking articles not otherwise provided for
• CPC Class Codes: G05B 2219/40006 Placing, palletize, un palletize, paper roll placing, box stacking
• CPC Class Codes: Y10T 83/2037 In stacked or packed relation
• CPC Class Codes: Y10T 83/204 Stacker sweeps along product support
• CPC Class Codes: Y10T 83/2057 Including means to deliver individual pieces to a stack holder

Abstract

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.

Claims

1. A programmable load forming system, comprising:

a robot comprising;

a moveable arm configured to carry at least one bundle; and

a robot controller that causes the moveable arm to perform a function; and

a computer operably coupled to the robot controller, the computer operable to communicate 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 a 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 moveable arm; and

determining if the moveable arm has completed moving along the calculated path, comprising continuously polling the robot controller to determine if the robot has completed moving along the calculated path, and if the robot has completed moving along the calculated path, downloading at least another calculated path from the computer to the robot controller while the robot returns to pick-up at least one additional bundle, the at least another calculated path defined, in part, by the stacking pattern, and moving the at least one additional bundle along the at least another calculated path to position the at least one additional bundle in at least another predetermined stacking position of the stacking pattern using the robot.

2. The programmable load forming system of claim 1 wherein:

the moveable arm comprises a gripping mechanism configured to carry the at least one bundle; and

the act of moving at least one bundle using the robot along the calculated path to position the at least one bundle in a stacking position of the stacking pattern comprises supporting the at least one bundle with a gripping mechanism of the robot.

3. The programmable load forming system of claim 1 wherein:

the programmable load forming system further comprises a build zone conveyor defining the build zone; and

the act of 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 comprises placing the at least one bundle at the predetermined stacking position over the build zone conveyor.

4. The programmable load forming system of claim 1, further comprising:

a conveyor operable to transport the at least one bundle to a location in which the moveable arm can pick-up the at least one bundle; and

a detector operable to detect the presence of the at least one bundle when the at least one bundle is at the location in which the moveable arm can pick-up the at least one bundle.

5. The programmable load forming system of claim 4 wherein the detector comprises one of an optical detector and an encoder.

6. The programmable load forming system of claim 1 wherein the computer includes a user interface configured for a user to input the stacking pattern.

7. The programmable load forming system of claim 6 wherein the user interface comprises a visual CAD interface.

8. A programmable load forming system, comprising:

a robot comprising;

a moveable arm;

a gripping mechanism operably connected with the moveable arm and moveable relative thereto, the gripping mechanism configured to carry at least one bundle; and

a robot controller that causes the moveable arm and gripping mechanism to perform a function;

a computer readable medium containing instructions for causing the robot to;

lower the at least one bundle onto a stack using the moveable arm and gripping mechanism of the robot;

responsive to the gripping mechanism moving a first predetermined distance relative the moveable arm upon encountering the stack, stop the at least one bundle from being lowered; and

move the gripping mechanism having the at least one bundle retained thereon upwardly a second predetermined distance prior to release of the bundle from the gripping mechanism onto the stack.

9. The programmable load forming system of claim 8 wherein the computer readable medium is included in the robot controller.

10. The programmable load forming system of claim 8, further comprising a computer including the computer readable medium, the computer operable to transmit the instructions to the robot controller.

11. The programmable load forming system of claim 8 wherein the act of moving the gripping mechanism having the at least one bundle retained thereon upwardly a second predetermined distance is responsive to instructions from an operator.

12. The programmable load forming system of claim 8 wherein the act of moving the gripping mechanism having the at least one bundle retained thereon upwardly a second predetermined distance occurs automatically upon the gripping mechanism moving the first predetermined distance.

13. The programmable load forming system of claim 8 wherein the instructions further comprise storing the second predetermined distance in a memory of the programmable load forming system.

14. The programmable load forming system of claim 8 wherein the moveable arm further comprises an air cylinder allowing the gripping mechanism to move the first predetermined distance relative to the moveable arm upon encountering the stack.

15. The programmable load forming system of claim 8, further comprising placing at least another bundle onto the stack at a height determined at least, in part, from the second predetermined distance.

16. A programmable load forming system, comprising:

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 moveable arm to move the at least one bundle along a predetermined path, the computer readable medium further comprising instructions for;

responsive to an operator signal, stopping the moveable arm from moving along the predetermined path and calculating a second path for moving the moveable arm from its stopped location to a reference location, the second path calculated such that the moveable arm is free from physical interference from other parts of the programmable load forming system as it travels along the second path to the reference location; and

automatically moving the moveable arm along the second path to the reference location.

17. The programmable load forming system of claim 16 wherein the computer readable medium is included in the robot controller.

18. The programmable load forming system of claim 16, further comprising a computer including the computer readable medium, the computer operable to transmit the instructions to the robot controller.

19. The programmable load forming system of claim 16, further comprising rotating a gripping mechanism of the moveable arm while the moveable arm is positioned at the reference location.

20. The programmable load forming system of claim 16 wherein operator signal is initiated when a joystick of the programmable load forming system is toggled.

21. The programmable load forming system of claim 16 wherein the act of moving the moveable arm from the first location to the reference location is terminated when a joystick of the programmable load forming system is released.