WO2017027909A1

WO2017027909A1 - A palletiser

Info

Publication number: WO2017027909A1
Application number: PCT/AU2016/050739
Authority: WO
Inventors: Peter Geoffrey Marks; Seyed Ali Mirfendereski; Justin Illingworth Hindle; Scott Alan Anderson; Kenneth James Orr; Jordan LEO
Original assignee: Foodmach Pty Ltd
Priority date: 2015-08-14
Filing date: 2016-08-12
Publication date: 2017-02-23
Also published as: CN107922131A; AU2016309947A1

Abstract

A palletiser (10) including a conveyor (11) for conveying generally square or rectangular objects to be palletised towards a palletising head (26). The palletising head (26) is rotatable and includes an abutment arrangement for engaging side surfaces of objects to be palletised. The abutment arrangement comprises first and second abutment groups (31) and (32) which are spaced apart on opposite sides of a centre line C of the palletising head (26) and each of which includes two spaced apart abutments (33, 34) which are operable to engage side surfaces of an object to be palletised. The spacing between the abutment groups (31) and (32) is adjustable and the spacing between the abutments (33, 34) of each of the first and second abutment (31) and (32) groups is adjustable. Upon engagement of an object to be palletised by the abutment arrangement, the palletising head (26) is operable to orientate the object through rotation of the palletising head (26) in order to form a selected pattern of objects on a pallet.

Description

A PALLETISER

Technical Field

[0001 ] The present invention relates palletising systems and equipment, for palletising objects for transport and/or storage. It will be convenient to describe the invention as is relates to the palletising of cartons, such as cardboard cartons which are generally square or rectangular in shape, within which objects are packaged, although it is to be appreciated that the invention is not limited just to the palletising of cartons. For example, the present invention can be employed for palletising shrink wrapped drink containers.

Background of Invention

[0002] A reference herein to prior art is not to be taken as an admission that that prior art was known or that it was part of the common general knowledge as at the priority date of any of the claims.

[0003] The function of a palletiser is to manipulate the position of objects on a moving conveyor into a position so that a particular pattern of objects can be formed for placement on a shipping pallet. The objects generally arrive at the palletiser in a uniform orientation and the gripping or clamping head of the palletiser is rotated on a robotic arm into a position in which it can grip or clamp one or more objects and thereafter, the object or objects are rotated to the appropriate orientation by rotation of the palletising head. The palletising head in some forms will then place the object or objects on a pallet, or in other forms, the palletising head will release the object or objects once correctly oriented for further conveyance to a pallet loading position. For example, the object or objects can be released on the conveyor for travel on the conveyor to a waiting pallet. Various different pallet patterns are assembled depending on the side and shape of the objects.

[0004] Palletising systems and equipment are used for positioning objects on pallets for transport and storage. As indicated above, the objects are often single cardboard cartons of square or rectangular configuration within which are packaged a plurality of items, such as foods items or drink containers. The objects alternatively can comprise a group of items which are assembled, grouped or placed together to form a square or rectangular body of items, but which are not otherwise fixed to each other. These items could be a plurality of small individual cartons for example, that are assembled for palletising into a larger group of cartons which group has an overall square or rectangular configuration or perimeter.

[0005] Particularly with this latter form of object, made up of a plurality of loosely placed or packed items (cartons for example), the speed of palletising is limited by the friction between the items within the group of items and care must be taken to drive the palletiser at a speed which does not cause relative displacement or shifting movement within the items of the group. Any shifting movement could disturb the shape of the group of items of the object and prevent proper placement or alignment of the object on a pallet.

[0006] In addition, objects for palletising can often be closely adjacent each other on a conveyer belt that feeds a palletiser and prior art palletisers often have palletising heads (the part of the palletiser that grips or clamps an object to be palletised) that are sufficiently bulky that either the palletising head will interfere with objects that are adjacent to the object that is to be clamped or gripped, or the adjacent objects will interfere with the palletising head. This can prevent an object from being properly clamped or gripped by the palletiser, thus affecting proper palletisation.

[0007] Current palletising systems are available in different forms. In some forms, the systems employ a pick and place arrangement in which an object on a conveyer is lifted from the conveyer and placed on a pallet in the correct orientation. Other forms of the palletising systems utilise grippers or clamps to grip or clamp objects and to rotate the objects on the conveying surface rather than lifting them from that surface. The present invention relates to the latter form of palletiser in which an object is manipulated as it remains on the conveying surface rather than being lifted from that surface.

[0008] In relation to the form of palletiser mentioned above, the applicant has recognised that a palletiser that can operate at a faster palletising speed than prior art systems would be desirable. The applicant has also recognised that a palletising head which is of compact form, so that objects adjacent to the object to be manipulated are not interfered with, would also be desirable.

Summary of Invention

[0009] According to the present invention there is provided a palletiser including: a conveyor for conveying generally square or rectangular objects to be palletised towards a palletising head; a palletising head which is rotatable and which includes an abutment arrangement for engaging side surfaces of objects to be palletised, the abutment arrangement comprising first and second abutment groups which are spaced apart on opposite sides of a centre line of the palletising head and each of which includes two spaced apart abutments which are operable to engage side surfaces of an object to be palletised , the spacing between the first and second abutment groups being adjustable and the spacing between the abutments of each of the first and second abutment groups being adjustable; upon engagement of an object to be palletised by the abutment arrangement, the palletising head being operable to orientate the object through rotation of the palletising head in order to form a selected pattern of objects on a pallet.

[0010] A palletiser according to the invention is operable to engage side surfaces of objects to be palletised in order to clamp or grip the object or objects. The palletising head can then orientate the object or objects so that they are in an orientation suitable to form a particular pattern when loaded on a pallet. A palletiser according to the invention can actually place the objects on a pallet, or it can position or orientate the objects for loading onto a pallet thereafter. A palletiser according to the invention can also advantageously position the first and second abutment groups and the abutments of those groups appropriately in order to properly clamp or grip the object or objects to be palletised. This ability to adjust the spacing of the first and second abutment groups and the abutments of those groups leads to [001 1 ] In a palletiser according to the invention, the two spaced apart abutments of the first and second abutment groups of can comprise two corner abutments which are operable to engage the respective corners of an object to be palletised. In this respect, the side surfaces of the object that are engaged by the abutments are the side surfaces at the corners of the object. Moreover, the first and second abutment groups can include at least one intermediate abutment that is positioned between the corner abutments.

[0012] In the above forms of the invention, a palletiser according to the invention is operable to more securely clamp or grip the object or objects to be palletised than some prior art arrangements. By adjusting the spacing of the abutments of the first and second abutment groups, the abutments can be positioned optimally for engaging the sides of the object or objects to be palletised. Where the object is a single object, the sides of the object can be engaged by both of the abutments. Where there are two objects grouped together, a respective abutment can engage the side of each object. Where there are three objects or more grouped together, not all of the objects need to be engaged but rather, reliance can be made on frictional engagement between the objects which are not engaged by an abutment, or alternatively, a greater number of abutments can be provided. For example, two corner abutments and one or more intermediate abutments could be provided in each of the first and second abutment groups to grip a three object group. In this latter arrangement, a palletiser according to the invention is operable to more securely clamp or grip the object or objects compared to some prior art arrangements in which clamping or gripping occurs only on opposite sides of the object or objects, rather than at the corners. In those prior art arrangements, excessive speed of movement of the palletiser head can be such that the object or objects shift relative to the palletiser head so that the object or objects are not positioned accurately when loaded onto the pallet. Accordingly, in those prior art arrangements, it is necessary to drive the palletising head at a speed in which shifting of the object or objects relative to the palletising head during clamping or gripping by the palletising head does not occur.

[0013] In contrast, where the palletising head of the present invention includes corner abutments which engage corners of an object or objects to be palletised, the object or objects are gripped or clamped in two different directions (X and Y directions), so that movement of an object relative to the palletiser during clamping or gripping by the palletising head is prevented. The palletising head can therefore be driven at a much faster rate than in some prior art arrangements. Increases in speed of drive have been estimated to be between 50% and 100%.

[0014] Moreover, as will be apparent from further description herein, the abutments of a palletiser according to the invention can be such as to only add marginally to the perimeter dimensions of the object or objects to be palletised. This means that the abutments will not ordinarily interfere with adjacent objects to be palletised, or in other words, adjacent objects to be palletised will not interfere with the proper gripping or clamping of an object or objects by the palletising head. In some forms of the present invention, the additional dimension added by the abutments of the first and second abutment groups to the perimeter dimensions of the object or objects to be palletised, is in the order of an extra 20mm, which is extremely minor and much less than many prior art arrangements.

[0015] Where corner abutments are provided, these can take any suitable form. In some forms of the invention, the corner abutments are formed of a right angle section so as to include sections that extend perpendicular to each other for engaging facing surfaces of the corner of an object to be palletised. Those facing surfaces of the object to be palletised are the faces on each side of the apex of the corner of the object to be palletised. The perpendicular length or depth of the respective sections of the right angle section can be equal or different, while the overall length or depth of the corner abutments must be sufficient to provide appropriate gripping or clamping load against the corners of the object to be palletised.

[0016] The corner abutments can also be of any suitable length to engage any suitable height portion of the corners of the object to be palletised. Thus, the corner abutments can be elongate to extend along a substantial length of the corner of the object, or they can engage the object only towards the top or bottom end or surface of the object. The elongate length of the corner abutments will be dependent on the type of objects to be palletised and the security of clamping engagement or gripping required. The overall length of the corner abutments might therefore vary depending on the dimensions of the objects to be palletised, and in some forms of the invention, the overall length of the corner abutments might be adjustable, telescopically adjustable for example.

[0017] Where intermediate abutments are provided, these can also be of any suitable shape or configuration. In some forms of the invention, the intermediate abutments can be of the same elongate length as the corner abutments. The intermediate abutments can be generally flat or planar given that they are for engaging or gripping a flat face of an object rather than the corner of an object. Alternatively, just the surface that will engage the objects to be palletised can be generally flat or planar. Thus, the shape of the portion of the intermediate abutment that does not engage the objects to be palletised can be of a different shape and can for example, include stiffening ribs for stiffening the intermediate abutments. In some forms of the invention, the intermediate abutments can have a generally rectangular cross-section, with the long sides of the cross-section being significantly longer than the short side. In other forms of the invention, the intermediate abutments can be elongate rods that have a circular cross-section.

[0018] The abutments of each abutment group, including where provided the corner abutments and the intermediate abutments of each abutment group, can be aligned in the same general plane. In this sense, where the corner abutments are formed to have a right-angle section, only one part of that section will strictly lie in the general plane mentioned above. The other part of that section will extend generally perpendicular to that plane. However, the corner abutments will be generally in the same plane.

[0019] The abutment groups can be aligned generally parallel to each other so that during adjustment of the spacing between the abutment groups, the abutments groups remain parallel. The adjustment in spacing can be a small relative movement between the abutment groups. The movement can be in the order of 50mm. The adjustment in spacing can be by one of the abutment groups moving toward and away from the other, so that one of the abutment groups remains stationary and the other moves, or both of the abutment groups can move. Where both of the abutment groups move, the movement can be to the same extent or to different extents. In most forms of the invention however, adjustment in spacing between the abutment groups is effected by simultaneous movement of both of the abutment groups to the same extent.

[0020] In order to adjust the spacing between the abutment groups, each abutment group can be connected to a bridging member and at least at one of the abutment groups can be moveable along the bridging member to adjust the spacing between the abutment groups. Any suitable arrangement can be provided to move the moveable abutment group.

[0021 ] In arrangements according to the invention in which each of the abutment groups is moveable so that adjustment of the spacing between the abutment groups comprises movement of the abutment groups towards and away from each other, the abutment groups can be connected to the bridging member along tracks that restrict the abutment movement to linear movement. The drive for the abutment groups can be by connection to a toothed belt, Vee belt or chain or the like, which extends about a pair of pulleys, wheels or gears, one of which is drivable in each of clockwise and anti-clockwise directions. Other forms of drive are applicable, including, hydraulic or pneumatic ram drive, worm gear drive and rack and pinion drive.

[0022] The benefit of the pulley, toothed wheel or gear drive described above, is that a single servo motor can be employed to drive one of the pulleys, toothed wheels or gears to effect adjustment of the spacing between each of the abutment groups.

[0023] Adjustment of the spacing between the abutments of each of the first and second abutment groups can be made in the same or a similar manner to adjustment in the spacing between the abutment groups. Thus, each of the abutments can be connected to a toothed belt, Vee belt or chain which extends about a pair of pulleys, wheels or gears, one of which is driven. Again, the other forms listed above for the abutment groups can be employed for the abutments to drive the abutments toward and away from each other.

[0024] Beneficially, the abutments of the two abutment groups can be moved together through a single drive arrangement, and this is typically desirable for objects for palletisation that are square or rectangular, as the abutments of the respective abutment groups generally will be positioned at the same position, such as at either ends of a square or rectangular object. Thus, in order to move the abutments of the respective abutment groups together, the respective abutments at each end of the abutment groups (corner abutments for example) can be connected together and the connection can be driven inwardly or outwardly to shift the positon of the abutments simultaneously.

[0025] In one form of the above arrangement incorporating corner abutments, the corner abutments at one end of the respective abutment groups are mounted on rods that extend inwardly to a mounting block and the mounting block is moved along a track resulting in movement of the two corner abutments with it. If the corner abutments at the other end of the abutment groups are also to be moveable, those corner abutments can be connected in the same manner as the other corner abutments and the respective mounting blocks of each pair of corner abutments can be connected to opposite sides of a belt in a drive arrangement of the kind discussed above which employs a toothed belt, Vee belt or chain or the like. The track can be mounted on a supporting member such as to which the palletising head is connected to a robot arm. In the above arrangement, the supporting member and the bridging member referred to earlier can be orientated perpendicular to each other to facilitate the different directions of movement that the respective members allow. Advantageously, the rods can be mounted to the mounting blocks for movement into and out of the mounting blocks to facilitate movement of the corner abutments and thus the abutment groups towards and away from each other as described above. This arrangement can also apply to abutments that are not corner abutments but that are at the same position in the respective abutment groups and that are intended to move together.

[0026] Like the abutment groups, the present invention covers arrangements in which all of the abutments are movable to vary the spacing between them. Alternatively the present invention also covers arrangements in which not all abutments are movable. For example, in abutment groups that have four abutments each, only two of the four abutments might be movable, such as the end or corner abutments of each of the two abutment groups. [0027] A palletising head according to the invention can thus alter the spacing between spaced apart abutment groups and between abutments that form part of those abutment groups. By this arrangement, opposite sides of a square or rectangular object can readily be gripped or clamped at appropriate positions. Where corner abutments are provided, the length and width, or X and Y dimensions of a square or rectangular object, such as a carton, can be gripped or clamped in each of the X and Y directions by the corner abutments and intermediate faces or surfaces of the carton can be gripped or clamped by any intermediate abutments that are provided. This has the benefit of providing a clamping or gripping force in two different directions and differs from the prior art that grips only on two opposite sides of an object at fixed positions. The present invention therefore does not rely on frictional engagement between the abutments and an object which is clamped or gripped, to maintain the position of an object in the direction in which there is no direct clamping or gripping load. One exception to this is where the object or objects to be clamped are smaller than the minimum gap that can be created between the corner abutments and the abutment groups. In that case, a combination of frictional engagement and gripping or clamping would be the mechanism by which a carton or cartons is secured by the palletising head.

[0028] In a palletiser according to the invention, a single intermediate abutment can be provided or a plurality of intermediate abutments can be provided. In some forms of the invention, each abutment group includes three intermediate abutments, and in other forms of the invention, eight or ten intermediate abutments are provided. The number of intermediate abutments can be influenced by the size of the palletising head and by the size of the objects that the palletising head is envisaged to work with.

[0029] In some forms of the invention, the palletiser does not include any intermediate abutments. In those forms of the invention, the palletiser includes four abutments only and these can be four end or corner abutments only. In other forms of the invention, the palletiser does not include corner abutments for engaging the corners of an object to be palletised, but rather, includes separate side abutments and optionally, end abutments in order to engage the ends of an object rather than the corners of the object. This arrangement enables an object to be engaged in one or two different and perpendicular directions (X and Y directions) by engagement of the sides and ends of an object. The engagement thus can be inboard of the corners of the objects rather than being at the corners.

[0030] Where the palletiser includes a single intermediate abutment in each of the abutment groups, that intermediate abutment of each group might be fixed rather than moveable. The intermediate abutment can therefore be positioned at a mid-point between the two end or corner abutments and remain in that position when the spacing between the end or corner abutments is altered.

[0031 ] Alternatively, two or more of the intermediate abutments where provided could be fixed and other intermediate abutments might be moveable with the end or corner abutments. Likewise, one end or corner abutment can be movable and one can be fixed and one or more intermediate abutments can be movable and others fixed. However in most forms of the invention, it is expected that each of the end or corner abutments and the intermediate abutment or abutments are movable to adjust the spacing between all of the respective abutments as required.

[0032] Where the intermediate abutments are movable with the end or corner abutments, any suitable arrangement can be employed to cause that movement. A geared arrangement can be employed for example. However, the applicant has developed a relatively simple arrangement that employs a flexible connector that can be resilient in addition to flexible. The flexible connector can connect to each of the end or corner abutments and the intermediate abutments and can act as a spacer and a spring. When the end or corner abutments and the intermediate abutments are at their maximum spacing, the flexible connector can be straight or at maximum extension. As the spacing between the corner abutments and the intermediate abutments reduces, the flexible connector can slacken. The flexible connector can droop and have no influence over the movement of the abutments, or in some forms the material of the flexible connector can be such as to resiliently displace away from straight into a sinusoidal or other relatively uniform shape between the abutments, while also maintaining a substantially equal distance between the abutments as they move. Thus, the flexible connector can operate to maintain a generally uniform spacing between abutments by its own resilience. In addition, as the abutments move away from each other, the flexible connector can return towards a straight condition, and in some resilient forms can continue to maintain a substantially equal distance between the abutments as they move.

[0033] As will be understood from above, the flexible connector is not required to be resilient. Applicant has employed webbing as the flexible connector and when webbing is used, the intermediate abutments will not necessarily move uniformly as the abutments move towards and away from each other. Rather, the intermediate abutments can float, so that the spacing between them will not be uniform, but ultimately they will return to maximum spacing when the webbing is at its maximum extension. This point of maximum spacing will also result in uniform spacing. This arrangement is simple and the movement of the abutments has been found to be acceptable.

[0034] Where an odd number of intermediate abutments is provided between end or corner abutments, there will usually be a middle or centre abutment that is fixed or static. Intermediate abutments on either side of the centre abutment can be arranged to move relative to the centre abutment.

Brief Description of Drawings

[0035] In order that the invention may be more fully understood, some embodiments will now be described with reference to the figures in which:

[0036] Figure 1 is a perspective view of a palletising system according to the invention.

[0037] Figure 2 is a perspective view of the palletising head of Figure 1 in a fully expanded position.

[0038] Figure 3 is a perspective view of the palletising head of Figure 1 in an intermediate position.

[0039] Figure 4 is a perspective view of the palletising head of Figure 1 in a fully retracted position.

[0040] Figures 5, 6 and 7 are underneath views of the palletiser head of Figures 2 to 4, in the fully expanded, intermediate and retracted positions respectively. [0041 ] Figure 8 is a partial view of an abutment group of the palletiser head of the earlier figures.

[0042] Figure 9 is a sequential illustration showing a partial view of the palletiser arrangement of Figure 1 manipulating cartons into a pallet pattern.

Detailed Description

[0043] Figure 1 illustrates in perspective view, a palletising system 10 which includes a conveyor 1 1 (only a portion of which is shown), that has a pair of belt conveyor sections 12 and 13. The conveyor sections 12 and 13 are separate sections that can be operated independently to run at different speeds. A group of three cartons 14 which have been assembled together upstream of the conveyor 12 are illustrated on the conveyor 12 with the direction of progress along the conveyor 1 1 being towards the conveyor 13. The group of three cartons 14 can be considered to constitute an "object" to be palletised as hereinbefore described.

[0044] The palletising system 10 includes a plurality of pallets in a pallet stack 19 which are loaded into the stacked position shown by forklift and which are fed to a palletising region 28 of the system 10 by an automated arrangement, and as each pallet of the pallet stack 19 is loaded to capacity, it is conveyed out of the system 10 to a dispatch position. The stacked pallet 21 is illustrated as being conveyed in that manner. The pallet 21 is shown loaded with 7 layers of cartons, each layer including 8 groups of 3 cartons (or 8 groups of 3 objects). The pallet 21 can be shifted to the end of the conveyor 22 for access by a forklift to be taken to a position either for transport or storage.

[0045] The manner in which the pallets of the pallet stack 19 are stacked and conveyed into the palletising region 28 and thereafter moved to the position of the pallet 21 is important for the operation of the palletising system 10 overall, but does not have significant influence on the invention described herein. Accordingly, there will be no further discussion in relation to the mechanisms provided for movement of pallets through the palletising system 10 as it is expected that a person skilled in the art would understand how those mechanisms operate. [0046] The palletising system 10 includes a robotic arm 25 and a robotic head 26. The robotic arm 25 is rotatable and is articulated, so that the head 26 can engage the carton group 14 and shift and rotate the group 14 as required to form the appropriate carton pattern as is being formed at the assembly section 27. As shown in Figure 1 , a carton group 15 is currently engaged by the head 26 for orientation. The carton group 15 is then conveyed to the assembly section 27, where groups of pre-orientated cartons are assembled into a particular pattern for conveying onto the palletising region 28. The palletising region 28 is formed on what is known as a "stripper", which is a supporting surface that is extended to support a layer of cartons conveyed thereto, and which can be withdrawn to allow the assembled layer to be loaded either directly on to the upper surface of a pallet of the pallet stack 19, or on top of a layer which has already been loaded on to a pallet. The operation of a stripper would be known to a person skilled in the art.

[0047] The operation of the system 10 is to load a pallet of the pallet stack 19 into position below the palletising region 28 and to then lay cartons onto the pallet. The pallet on which the cartons have been loaded is progressively lowered as carton layers are added until such time as seven layers have been loaded onto the pallet. The loaded pallet is then conveyed away from the palletising region 28 as is initially shown by pallet 29.

[0048] The robotic arm 25 can rotate about a vertical axis, and the articulated sections of the arm 25 allow the arm 25 to raise and lower the head 26. Thus, the head 26 can be shifted through three-dimensional movement.

[0049] The head 26 of the palletising system 10 has a unique construction which offers significant benefits to the operation of the system 10. The robotic head 26 is illustrated individually and separate from the other components of the system 10 in Figures 2 to 4.

[0050] Figures 2 to 4 show the head 26 in three different configurations, being a fully open position in Figure 2, and fully closed position in Figure 4, and an intermediate position between open and closed in Figure 3. With reference to each of Figures 2 to 4, the head 26 includes abutments for engaging side surfaces of objects, such as the cartons shown in Figure 1 , which are to be palletised. In the figures, the abutments comprise first and second abutment groups 31 and 32 which are spaced apart on opposite sides of a centre line C of the head 26 and which comprise a pair of corner abutments 33 and a plurality of intermediate abutments 34. Three intermediate abutments 34 are shown but there could be more or less. In the illustrated form of the invention and in forms of the invention that are not illustrated, only a single intermediate abutment might be provided, or two, four or more intermediate abutments 34 could be provided. In addition, while corner abutments have been shown, these could be end abutments which form the end most abutments of each of the abutment groups 31 and 32, but which are not formed to have a right-angled cross-section as illustrated.

[0051 ] The corner abutments 33 are formed to have a right-angled cross-section, while the intermediate abutments 34 are flat. The cross-section of the intermediate abutments 34 could be altered to increase the stiffness of the abutments if required, such that the intermediate abutments 34 could be T-shaped in cross-section for example. The corner abutments 33 are intended to engage corners of an object to be palletised, while the intermediate abutments 34 are intended to engage against side surfaces of the object, inboard of the corners. The corner abutments 33 therefore are intended to engage on either side of the apex of a corner, being surfaces at the corner which are substantially perpendicular to each other. By this arrangement, when the corner abutments 33 engage the corners of an object to be palletised, the object is securely held or retained in each of the X and Y axes. This advantageously means that movement of the object in the Y direction is resisted by the X component of the corner abutments 33, identified by reference numeral 33-i , while movement of the object in the X direction is resisted by the Y component of the corner abutments 33, identified by reference numeral 33₂ as well as by the three intermediate abutments 34. It will be evident that in some forms of the invention, movement of an object in the X direction can be resisted by the Y component 33₂ of the corner abutments 33 only and without the need for any of the intermediate abutments 34. However, the use of at least one intermediate abutment is preferred.

[0052] To accommodate cartons of different dimensions, the abutment groups 31 and 32 can move toward and away from each other in the X direction, while the corner abutments 33 and the intermediate abutments 34 can move in the Y direction. This is illustrated in Figures 3 and 4, in which in Figure 3, the abutment groups 31 and 32 have been moved together in the X direction and the corner abutments 33 and intermediate abutments 34 have been moved together in the Y direction. In Figure 3 however, there is still further movement that can be provided through the abutment groups 31 and 32 and the corner and intermediate abutments 33 and 34, and that further movement is shown in Figure 4. Thus, in Figure 4, the smallest form of object that can be gripped or engaged by the abutment groups 31 and 32 is shown, while the maximum form of object is that which is shown in Figure 2.

[0053] The abutment groups 31 and 32 are mounted on rods 36 and 37 at each end of the groups 31 and 32. The rods 36 and 37 are fixed at either end to the abutment groups 31 and 32 and at opposite ends, are slidably accommodated within mounting blocks 38. This is also evident in Figure 5, which is an underneath view of the palletising head 26. The rods 36 and 37 are slightly offset in the Y direction and each extends through a dedicated opening through the respective mounting blocks 38. As shown in Figures 6 and 7, as the rods 36 and 37 push through the mounting blocks 38, they extend towards opposite sides of the palletising head 26.

[0054] The mechanism that drives movement of the abutment groups 31 and 32 towards each other is illustrated in Figures 5 to 7 and include toothed wheels 40 and 41 about which a toothed 42 belt extends. The toothed wheel 40 is driven by an electric servo motor 43. The position of the toothed wheel 41 is adjustable via a simple adjustment mechanism 44 (see Figure 2 to 4), so that the tension in the toothed belt 42 can be appropriately set.

[0055] In addition, the respective abutment groups 31 and 32 are attached to opposite sides of the belt 42, so that rotation of the toothed wheel 40 in clockwise direction moves the belt 42 in the directions shown by the arrows of Figure 5 and so that the abutments groups 31 and 32 will move towards each other. Rotation of the toothed wheel 40 in an anti-clockwise direction will move the abutment groups 31 and 32 in the opposite direction away from each other. The respective abutment groups 31 and 32 are attached to mounting brackets 55, which are slidably fixed to tracks 57 which extend lengthwise along the underside of the bridging member 56. The abutment groups 31 and 32 are thus connected to the rods 36 and 37, to the belt 42 and to the tracks 57 of the bridging member 56 via the mounting brackets 55.

[0056] The same general arrangement is employed to drive the corner and intermediate abutments 33 and 34 towards and away from each other. Again, with reference to Figure 5, a servo motor 50 (also seen in Figures 2 to 4), is operable to rotate a first toothed wheel 51 which drives toothed belt 52 about a second toothed wheel 51 . The respective mounting blocks 38 are fixed to opposite sides of the toothed belt 42, so that rotation of the toothed wheel 51 in a clockwise direction as shown in Figure 5, moves the mounting blocks 38 towards each other, while movement in the anti-clockwise direction, moves them apart.

[0057] By rotation of toothed wheels 51 , the mounting blocks 38 can be moved towards each other (or away from each other), and by that movement, the corner abutments 33 which are attached to the rods 36 and 37, also move towards each other. That movement is along tracks 53 on which each of the corner and intermediate abutments 33 and 34 are mounted for sliding movement. While the tracks 53 are shown in Figures 2 and 5, they are also apparent from Figures 3, 4, 6 and 7. The tracks 53 are connected to mounting plates 54 which attach to the mounting brackets 55, which, as described earlier, are slidably fixed to the underside of the bridging member 56 on tracks 57.

[0058] The corner and intermediate abutments 33 and 34 slidably engage the track 53 as shown in Figure 8. In Figure 8, various components of the abutment group 32 have been omitted in order to show the track 53 and the mating sliding blocks 59 that engage the track 53. In particular, the flexible connector 60, which is shown in other figures, is omitted.

[0059] From Figure 8, it will appear that upon movement of the corner abutments 33 towards and away from each other, the intermediate abutments 34 will not be caused to move. However, with the addition of the flexible connector 60 illustrated in each of the other figures, movement of all of the abutments 33 and 34 takes place upon movement of the corner abutments 33 towards or away from each other. [0060] The flexible connector 60 can shift between the fully straight position shown in Figures 2 and 5, through the intermediate position shown in Figures 3 and 6, and finally to the end position as shown in Figures 4 and 7. The flexible connector 60 can just be flexible, or it can be resilient in that it applies a movement load to the intermediate abutments 34 as the corner abutments 33 move relative to each other, to either move the intermediate abutments 34 towards each other and thus towards the position shown in Figure 7, or away from each other, back to the position shown in Figure 5. The flexible connector 60 thus acts in the manner of a spring so that the spacing between the respective abutments 33 and 34 is generally even between the extended and retracted positions of Figures 5 and 7. As readily seen in Figures 2 and 3, the flexible connector 60 is fixed to the corner and intermediate abutments 33 and 34 at fixing positions 61 , so that as the corner abutments 33 begin to move towards each other from the extended position of Figure 2, the connector 60 starts to flex towards the sinusoidal position of Figure 6 and in doing so, the flexible connector 60 causes the intermediate abutments 34 to shift towards each other. In Figure 7, the flexible connector 60 has reached its maximum point at which it is operable to move the intermediate abutments 34, given that the sections of the connector 60 not connected to the abutments 33 or 34 are generally parallel.

[0061 ] Upon movement of the corner abutments 33 from the retracted position of Figure 7 back through the intermediate position of Figure 6 and the extended position of Figure 2, the flexible connector 60 pushes the intermediate abutments 34 to maintain their even separation between themselves and between the corner abutments 33.

[0062] The flexible connector 60 can be formed from any suitable material, such as fabric webbing, polyurethane, rubber or similar.

[0063] Alternative arrangements to the flexible connector 60 could easily be adopted and could comprise suitable gearing or rack and pinion arrangements, however the use of the flexible connector 60 has been found to be both effective and simple and therefore highly acceptable. [0064] Movement of the abutments 33 and 34 in the manners described above can be very quick. Accordingly, the abutment groups 31 and 32 and the abutments 33 and 34 within those groups, can be shifted to a position in which to receive an object and then to a position to grip or clamp an object very quickly. In most cases, the amount of movement required is not very great, as the abutments can be positioned with only small clearance to receive an object before being shifted a small amount to clamp or grip the object so that the orientation of the object can be manipulated. In some applications of the present invention, the objects to be manipulated by the palletising head 26 will all be of the same dimensions for each palletising job, so that the same repetitive movement between open and gripping or clamping positions will be made by the abutment groups 31 and 32 over and over again. In other applications of the present invention, while the objects to be manipulated by the palletising head 26 will all be of the same dimensions the palletising head is required to grip or clamp multiple cartons and the number of cartons per grip or clamp will vary, so that a different movement between open and gripping or clamping positions will be made by the abutment groups 31 and 32 for each gripping or clamping movement. This can occur when a particular palletising pattern requires different numbers of cartons to be grouped together in different sections of the pattern. Where the objects are cartons, the variation in dimensions from one carton to the next will be negligible, but the dimension of the carton group will change.

[0065] The principle function of the palletising head 26 is to grip or clamp an object (a carton or group of cartons for example) and to orient the object for proper loading onto a pallet. Figure 9 illustrates a sequence of movements of the palletising head 26 in order to complete one layer of cartons for loading onto a pallet. The first image of Figure 9 shows cartons 14 being conveyed toward the palletising head 26 and subsequent images show the cartons 14 being shifted and rotated. The images show additional cartons 14 being shifted and rotated to form the final pallet pattern illustrated in the final image of Figure 9. All of the cartons in this example are of the same dimension and simply require appropriate positioning and orientation. Once the layer of cartons has been formed, the layer can be conveyed onto the surface of a pallet, or onto a preceding layer of cartons that has already been loaded onto the pallet. [0066] A major advantage of the pallet head 26 as illustrated and described above, is that the cartons illustrated in Figure 9 are gripped in each of two directions at the corners of the carton. This differs from some prior art arrangements in which gripping or clamping of a carton is only against one pair of opposite sides of the carton and not against the carton ends. With that prior art arrangement, when the head is moved rapidly, the cartons can shift relative to the head, so that the final position they assume for palletising is incorrect. Moreover, certain palletising heads are used to clamp or grip groups of cartons or objects, and again, upon rapid movement of the palletising head, cartons or objects within the group can shift relative to the remainder of the group. The invention provides for gripping or clamping cartons at their corners or at each of the ends and sides of the cartons so that in each case, gripping or clamping occurs in the X and Y directions.

[0067] In the above arrangement whereby clamping or gripping of an object is along opposite sides only, the speed of palletising is limited by the friction between the palletiser and the object, or between the plurality of items that might make up an object. The present invention dispenses reliance on friction by gripping the object in two directions.

[0068] Tests conducted by the applicant indicate that an increase in palletising speed might be in the order of 50% to 100% when compared to prior art palletising arrangements.

[0069] Another major advantage provided by the palletiser as illustrated in the figures, is that the corner and intermediate abutments 33 and 34 are very slim and therefore do not add significantly to the dimensions of the objects being clamped or gripped. For example, the extended Figure 2 arrangement can be suitable to grip an object or multiple objects having an overall dimension of 1200mm x 600mm, while the Figure 4 retracted arrangement can define internal dimensions of 150mm x 100mm. The thickness of the intermediate abutments 34 only adds about another 20mm on each side of the object or objects. Accordingly, the abutments 33 and 34 are unlikely to interfere with objects that are closely adjacent the object which is being gripped or clamped because the spacing between objects on conveyers tends to be much greater than 20mm. [0070] Accordingly, the palletising head 26 illustrated in the figures is more compact than some prior art arrangements, and can operate at a faster rate than comparable prior art arrangements. Despite this, the cost of the palletising head in not significantly greater than prior art arrangements and the advantages that the palletising head 26 provides are considered to greatly outweigh any increase in cost.

[0071 ] Throughout the description and claims of the specification, the word "comprise" and variations of the word, such as "comprising" and "comprises", is not intended to exclude other additives, components, integers or steps.

[0072] The invention described herein is susceptible to variations, modifications and/or additions other than those specifically described and it is to be understood that the invention includes all such variations, modifications and/or additions which fall within the spirit and scope of the present disclosure.

Claims

CLAIMS:

1 . A palletiser including:

a conveyor for conveying generally square or rectangular objects to be palletised towards a palletising head; a palletising head which is rotatable and which includes an abutment arrangement for engaging side surfaces of objects to be palletised, the abutment arrangement comprising first and second abutment groups which are spaced apart on opposite sides of a centre line of the palletising head and each of which includes two spaced apart abutments which are operable to engage side surfaces of an object to be palletised, the spacing between the first and second abutment groups being adjustable and the spacing between the abutments of each of the first and second abutment groups being adjustable; upon engagement of an object to be palletised by the abutment arrangement, the palletising head being operable to orientate the object through rotation of the palletising head in order to form a selected pattern of objects on a pallet.

2. A palletiser according to claim 1 , the spaced apart abutments of the first and second abutment groups comprising corner abutments which are operable to engage the respective corners of the side surfaces of an object to be palletised.

3. A palletiser according to claim 2, the corner abutments including a right angle section for engaging perpendicular surfaces of a corner of an object to be palletised.

4. A palletiser according to claim 2 or 3, the corner abutments being elongate.

5. A palletiser according to anyone of claims 2 to 4, each of the first and second abutment groups further including at least one intermediate abutment that is positioned between the corner abutments and which is operable to engage a side surface of an object to be palletised between the corners of the object.

6. A palletiser according to claim 5, the intermediate abutments being elongate.

7. A palletiser according to claim 5 or 6, the corner abutments and the intermediate abutment of each abutment group being aligned in the same general plane.

8. A palletiser according to claim 7, the abutment groups being aligned generally parallel to each other.

9. A palletiser according to anyone of claims 2 to 8, the corner abutments and the intermediate abutments extending generally vertically from an upper track, at least one of the corner abutments being movable along the track to adjust the spacing between the corner abutments.

10. A palletiser according to claim 9, each of the corner abutments being movable along the track.

1 1 . A palletiser according to anyone of claims 2 to 10, each abutment group including a plurality of intermediate abutments between the corner abutments and the spacing between the intermediate abutments being adjustable.

12. A palletiser according to claim 1 1 , the corner abutments and the intermediate abutments of each abutment group being aligned in the same general plane.

13. A palletiser according to claim 1 , each abutment group including three or more abutments and the abutments of each abutment group being aligned in the same general plane.

14. A palletiser according to claim 1 or 13, the abutment groups being aligned generally parallel to each other.

15. A palletiser according to anyone of claims 1 to 14, the spacing between the first and second abutment groups being adjustable by movement of the abutment groups towards or away from each other.

16. A palletiser according to claim 15, the movement of the abutment groups towards or away from each other being movement which is substantially perpendicular to the centre line of the palletising head.

17. A palletiser according to anyone of claims 1 to 16, the spacing between the abutments of each of the first and second abutment groups being adjustable by movement of the abutment within each group towards or away from each other.

18. A palletiser according to claim 17, the movement of the abutments of each of the first and second abutment groups towards or away from each other being movement which is substantially parallel to the centre line of the palletising head.

19. A palletiser according to anyone of claims 1 to 18, the abutment groups being connected to a bridging member and at least one of the abutment groups being movable along the bridging member to adjust the spacing between the abutment groups.

20. A palletiser according to claim 1 , the abutments of the first and second abutment groups comprising at least three abutments which comprise two corner abutments which are operable to engage the respective corners of the side surfaces of an object to be palletised and an intermediate abutment that is positioned between the corner abutments and which is operable to engage a side surface of an object to be palletised between the corners of the object, the intermediate abutment being fixed relative to the corner abutments and the corner abutments being adjustable by movement of the corner abutments towards and away from each other and towards and away from the intermediate abutment.

21 . A palletiser according to claim 1 , the abutments of the first and second abutment groups comprising at least four abutments which comprise two corner abutments which are operable to engage the respective corners of the side surfaces of an object to be palletised and two intermediate abutments that are positioned between the corner abutments and which are operable to engage a side surface of an object to be palletised between the corners of the object, each of the corner abutments and the intermediate abutments being movable to adjust the spacing between the abutments.

22. A palletiser according to claim 21 , the abutments of the first and second abutment groups being connected by a connector that maintains the spacing between the abutments substantially equal as the spacing between the abutments is adjusted.

23. A palletiser according to claim 22, the connector being a flexible and resilient connector.

24. A palletiser according to claim 22, the abutments of the first and second abutment groups being connected by a connector, the connector being a flexible connector.

25. A palletising head which is rotatable and which includes an abutment arrangement for engaging side surfaces of objects to be palletised, the abutment arrangement comprising first and second abutment groups which are spaced apart on opposite sides of a centre line of the palletising head and each of which includes two spaced apart abutments which are operable to engage side surfaces of an object to be palletised, the spacing between the first and second abutment groups being adjustable and the spacing between the abutments of each of the first and second abutment groups being adjustable.