Random case sealer

Abstract

Various embodiments of the present disclosure provide a random case sealer. The case sealer includes a top-head-actuating assembly configured to vary the speed of the top-head assembly when ascending (to make room for the case beneath the top-head assembly) and when descending onto the case (to engage the top surface of the case during sealing). This maximizes the speed of the top-head assembly while limiting overshoot (when ascending) and preventing damage to the case (when descending). In certain embodiments the case sealer includes a tape cartridge configured to limit the forces imparted onto the leading and top surfaces of the case during sealing. These features result in increased throughput as compared to prior art random case sealers without requiring stronger cases or more protective dunnage.

1 . A method of operating a case sealer, the method comprising:
 determining that a first event occurred;   responsive to determining that the first event occurred, begin raising a top-head assembly of the case sealer;   determining that a second event occurred after the first event;   responsive to determining that the second event occurred, slowing the ascent of the top-head assembly without stopping the ascent of the top-head assembly;   determining that a third event occurred after the second event; and   responsive to determining that the third event occurred, enabling the top-head assembly to stop ascending.   
     
     
         2 . The method of  claim 1 , wherein determining that a first event occurred comprises determining that a first sensor and a second sensor have each detected a case. 
     
     
         3 . The method of  claim 2 , wherein determining that the second event occurred comprises determining that the second sensor no longer detects the case while the first sensor continues to detect the case. 
     
     
         4 . The method of  claim 3 , wherein determining that the third event occurred comprises determining that the first sensor no longer detects the case. 
     
     
         5 . The method of  claim 4 , further comprising:
 enabling the top-head assembly to begin descending after the top-head assembly stops ascending;   determining that a fourth event occurred after the third event; and   responsive to determining that the fourth event occurred, slowing the descent of the top-head assembly without stopping the descent of the top-head assembly.   
     
     
         6 . The method of  claim 5 , wherein determining that the fourth event occurred comprises determining that a third sensor detects the case below the top-head assembly. 
     
     
         7 . The method of  claim 6 , further comprising, responsive to the occurrence of the third event, enabling the top-head assembly to begin descending under its own weight after the top-head assembly stops ascending. 
     
     
         8 . The method of  claim 6 , further comprising, responsive to the occurrence of the third event, controlling an actuator to begin lowering the top-head assembly. 
     
     
         9 . The method of  claim 1 , further comprising:
 enabling the top-head assembly to begin descending after the top-head assembly stops ascending;   determining that a fourth event occurred after the third event; and   responsive to determining that the fourth event occurred, slowing the descent of the top-head assembly without stopping the descent of the top-head assembly.   
     
     
         10 . The method of  claim 1 , wherein determining that the first event occurred comprises determining that a case has reached the top-head assembly when the top-head assembly is at a lower position. 
     
     
         11 . The method of  claim 10 , wherein determining that the third event occurred comprises determining that the top-head assembly has risen above a top surface of the case. 
     
     
         12 . The method of  claim 11 , wherein determining that the second event occurred comprises determining that the top-head assembly has reached a position between the lower position and a position at which the top-head assembly is located upon the occurrence of the third event. 
     
     
         13 . The method of  claim 12 , further comprising:
 enabling the top-head assembly to begin descending after the top-head assembly stops ascending;   determining that a fourth event occurred after the third event; and   responsive to determining that the fourth event occurred, slowing the descent of the top-head assembly without stopping the descent of the top-head assembly.   
     
     
         14 . The method of  claim 13 , wherein determining that the fourth event occurred comprising determining that the case is below the top-head assembly. 
     
     
         15 . The method of  claim 14 , further comprising:
 after the occurrence of the fourth event, engaging the top surface of the case with the top-head assembly;   moving the case into engagement with and past a tape cartridge; and   applying, by the tape cartridge, tape to an upper surface of the case as the case moves past the tape cartridge.   
     
     
         16 . The method of  claim 12 , further comprising:
 enabling the top-head assembly to begin descending after the top-head assembly stops ascending; and   after the case has been positioned below the top-head assembly:
 engaging the top surface of the case with the top-head assembly; 
 moving the case into engagement with and past a tape cartridge; and 
 applying, by the tape cartridge, tape to an upper surface of the case as the case moves past the tape cartridge. 
   
     
     
         17 . A method of operating a case sealer, the method comprising:
 determining that a case has reached a top-head assembly of the case sealer when the top-head assembly is at a lower position;   responsive to determining that the case has reached the top-head assembly when the top-head assembly is at the lower position, controlling an actuator to begin raising the top-head assembly;   determining that the top-head assembly has reached a designated position above the lower position but below a top surface of the case;   responsive to determining that the top-head assembly has reached the designated position, controlling the actuator to slow the ascent of the top-head assembly without stopping the ascent of the top-head assembly;   determining that the top-head assembly has risen above the top surface of the case; and   responsive to determining that the top-head assembly has risen above the top surface of the case, controlling the actuator to enable the top-head assembly to stop ascending.   
     
     
         18 . The method of  claim 17 , further comprising controlling the actuator to enable the top-head assembly to descend after the top-head assembly has stopped ascending. 
     
     
         19 . The method of  claim 18 , further comprising:
 determining that the case has been positioned below the top-head assembly after the top-head assembly has risen above the top surface of the case; and   responsive to determining that the case has been positioned below the top-head assembly, controlling the actuator to slow the descent of the top-head assembly without stopping the descent of the top-head assembly.   
     
     
         20 . The method of  claim 19 , further comprising:
 engaging the top surface of the case with the top-head assembly;   moving the case into engagement with and past a tape cartridge; and   applying, by the tape cartridge, tape to an upper surface of the case as the case moves past the tape cartridge.