End Effector for Picking, Forming, and Inserting U-Shaped Packing Insert

Abstract

End of arm tool ( 10 ) is used to load goods A and B in two layers in a packing container ( 8 ), with a packing insert positioned between the layers. The tool ( 10 ) also grasps a packing insert in the form of a flat sheet, bends the ends of the packing sheet downwardly to form an inverted U shape, and then inserts the packing insert in a straddling relationship about the lower layer of goods A, to protect the lower layer of goods from the weight applied by the upper layer of goods.

1 . An end of arm tool for mounting to the end of an arm of a robot, for picking a generally flat work product at an intermediate portion of the work product, bending the oppositely extending lateral sides of the work product into a U-shape with respect to said intermediate portion of the work product, and placing the U-shaped product in a container, said end of arm tool comprising:
 a tool support,   a vacuum plenum housing supported by said tool support,   at least one vacuum retriever extending downwardly from said vacuum plenum housing for engaging the work product,   a pair of forming arms each including proximal end portions pivotally supported at a level above said vacuum retriever and distal end portions on opposite sides of said vacuum retriever and pivotal from positions above said vacuum retriever and out of engagement with the work product to substantially parallel positions extending below said vacuum retriever for engaging and bending the oppositely extending lateral sides of the work product into a U-shape.   
     
     
         2 . The end of arm tool of  claim 1 , wherein said vacuum retriever comprises a plurality of suction cups suspended in a downward direction. 
     
     
         3 . The end of arm tool of  claim 1 , and further including discharge means movable between retracted positions at a level of said vacuum retriever to distended positions below said vacuum retriever for urging the U-shaped work product away from said vacuum retriever and for urging the lateral sides of the work product into the container. 
     
     
         4 . The end of arm tool of  claim 1 , wherein the work product to be picked includes score lines dividing said work product into the intermediate portion and the oppositely extending lateral sides, and said vacuum retriever of said end of arm tool being arranged to engage the intermediate portion and said forming arms arranged to engage and bend the oppositely extending lateral sides of the work product about the score lines. 
     
     
         5 . The end of arm tool of  claim 1 , wherein the container includes upwardly and outwardly sloped closure flaps, and said pair of forming arms are configured to tuck the oppositely extending lateral sides of said work product downwardly between said closure flaps. 
     
     
         6 . A tool for picking a generally flat work product, the work product including an intermediate portion and oppositely extending side portions, and for bending the work product into a U-shape, and for placing the opposite side portions into a container, said tool comprising
 a tool support,   a plurality of vacuum retrievers suspended by said tool support for picking the intermediate portion of the work product,   a pair of forming arms mounted to said tool support including distal ends movable from retracted positions at said vacuum retrievers to extended positions on opposite sides of and lower than said vacuum retrievers for engaging and bending the side portions of the work product to form the work product into a U-shape, and   discharge means supported by said tool support for urging the U-shaped work product away from said vacuum retrievers.   
     
     
         7 . The tool of  claim 6 , wherein said pair of forming arms include proximal ends pivotally supported by said tool support at a level above said plurality of vacuum retrievers and distal ends pivotal from outwardly extending positions above said vacuum retrievers and out of engagement with the work product to positions extending below said vacuum retrievers for engaging and bending the oppositely extending portions of the work product. 
     
     
         8 . The tool of  claim 6 , wherein the generally flat work product includes score lines between said intermediate portion and oppositely extending side portions, and said pair of forming arms configured to engage the oppositely extending side portions and bend the side portions about the score lines of the work product. 
     
     
         9 . The tool of  claim 6 , wherein the forming arms of said pair of forming arms each comprise distal ends pivotal from positions out of engagement with the work product to positions extending below said vacuum retrievers for engaging and bending the portions of the work product extending laterally from said vacuum retrievers. 
     
     
         10 . The tool of  claim 6 , wherein said tool is mounted to the end of an arm of a robot. 
     
     
         11 . The tool of  claim 6 , wherein said discharge means includes pusher means movable from the level of said vacuum retrievers downwardly from said vacuum retrievers into engagement with the work product for pushing the work product away from the vacuum retrievers. 
     
     
         12 . The tool of  claim 6  wherein said discharge means comprises fluid actuated cylinders that distend piston rods against the work product. 
     
     
         13 . The tool of  claim 6  wherein said forming arms of said pair of forming arms each include an elongated proximal end and an elongated distal end, with the distal end forming an obtuse angle for tucking the oppositely extending side portions of the work product into the container when said forming arms straddle the intermediate portion of the work product. 
     
     
         14 . The tool of  claim 6 , wherein said discharge means comprises pusher means supported by said tool support movable between retracted positions at a level of said vacuum retrievers to distended positions below said vacuum retrievers. 
     
     
         15 . The tool of  claim 6  and further including power means carried by said tool support and operably connected to said forming arms to tilt the distal ends of said forming arms toward each other and into bending engagement with the side portions of said work product. 
     
     
         16 . The tool of  claim 15 , wherein said power means comprises fluid operated cylinders mounted on said tool support. 
     
     
         17 . A tool for picking a generally flat work product, the work product including an intermediate portion and oppositely extending side portions, and for bending the work product into a U-shape, and for placing the opposite side portions into a container, said tool comprising
 a plurality of vacuum retrievers for picking the intermediate portion the work product,   a pair of forming arms including distal ends movable from retracted positions at said vacuum retrievers to extended positions on opposite sides of and lower than said vacuum retrievers for engaging and bending the side portions of the work product to form the work product into a U-shape, and   discharge means for urging the intermediate portion of the U-shaped work product away from said vacuum retrievers.   
     
     
         18 . The tool of  claim 17 , wherein said discharge means is positioned among said plurality of vacuum retrievers. 
     
     
         19 . The tool of  claim 17 , wherein said discharge means comprises at least one fluid operated cylinder and piston rod, said piston rod movable intermediate said vacuum retrievers downwardly into engagement with the intermediate portion of the U-shaped work product. 
     
     
         20 . The tool of  claim 19 , wherein said at least one fluid operated cylinder comprises a plurality of fluid operated cylinders. 
     
     
         21 . The tool of  claim 17 , and further including a vacuum plenum housing, said vacuum retrievers in fluid communication with said vacuum plenum housing. 
     
     
         22 . A method of inserting a work product into a container using the tool of  claim 17 , comprising
 applying said tool to a substantially flat work product,   grasping an intermediate portion of the work product with said vacuum retrievers and moving the work product over an open top container,   folding the opposed side portions of the work product with said pair of forming arms to form the work product into an inverted U shape with the side portions of the work product extending downwardly,   moving the work product downwardly and as the work product moves downwardly inserting the folded side portions of the work product into the container until the intermediate portion of the work product is substantially even with the opening of the container,   lifting said tool away from the container, and   as said tool is lifted away from the container releasing said vacuum retrievers from the work product, and   pushing said discharge means against the work product to maintain the work product in the container.   
     
     
         23 . A method of placing a divider over the goods in a shipping container, comprising:
 bending with an end of arm tool the divider into an inverted U-shape including an intermediate portion and lateral end portions,   placing with the end of arm tool the divider over the shipping container with the intermediate portion of the divider extending over the goods in the shipping container and the lateral end portions of the divider directed downwardly between the goods and the vertical sides of the shipping container,   pushing with fluid actuated evacuating means extended from the end of arm tool against the intermediate portion of the divider to move the divider into the container.