AUTOMATED CONTAINER CUTTING APPARATUS, A SYSTEM INCLUDING THE APPARATUS, AND A METHOD OF CUTTING A CONTAINER

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application Ser. No. 63/657,651, filed by Darian Carr, et al. on Jun. 7, 2024, entitled “AUTOMATED CONTAINER CUTTING APPARATUS, A SYSTEM INCLUDING THE APPARATUS, AND A METHOD OF CUTTING A CONTAINER,” commonly assigned with this application and incorporated herein by reference in its entirety.

TECHNICAL FIELD

This application relates to an automated process for opening containers, and more specifically, to automatically cutting containers, such as boxes, that may have one or more sides that are non-planar.

BACKGROUND

Retailers, distributors, warehouses, and other similar facilities receive products packed in containers, such as boxes or other types of containers that are used to ship products. The received containers are opened to allow for removal and processing of the products. Typically, the containers are opened by cutting the top of the container or one or more sides of the container. The containers can be manually or automatically opened.

SUMMARY

In one aspect, the disclosure provides an automated container cutting system for containers. In one example the automated container cutting system includes: (1) a compliant cutting tool having a repositionable blade, and a controller configured to direct cutting of a container by moving the compliant cutting tool along a cutting path while the compliant cutting tool follows a cut line on an outer surface of the container.

In another aspect, the disclosure provides a compliant cutting tool. In one example, the compliant cutting tool includes: (1) a wear plate that contacts one or more outer surfaces of a container during cutting and positions a blade against the outer surfaces during the cutting, and (2) a mechanical interface configured to control repositioning of the blade for the cutting.

In yet another aspect, another cutting tool is disclosed. In one example, the cutting tool include: (1) a wear plate that contacts one or more outer surfaces of a container during cutting and positions a blade against the one or more outer surfaces during the cutting, and (2) a blade bank having multiple blades.

BRIEF DESCRIPTION

The foregoing summary, examples, and other aspects of the subject matter of the present disclosure will be better understood with reference to the following detailed description of examples when read in conjunction with the accompanying drawings, in which:

FIG. 1 illustrates a side view of an example of a box having products;

FIGS. 2A to 2E illustrate top views of the box of FIG. 1 showing examples of planar and non-planar sides, different cut lines, and different cutting paths;

FIG. 2F illustrates a compliant cutting tool that compensates for the peaks and valleys of contoured cut line while being moved by moveable support along the straight cutting path;

FIG. 3 illustrates an example of blade depth and blade angle with respect to a blade according to the principals of the disclosure;

FIG. 4 illustrates a block diagram of an example of compliant cutting tool constructed according to the principles disclosed herein.

FIG. 5 illustrates a block diagram of an example of an automated container cutting system constructed according to the principles of the disclosure;

FIG. 6 illustrates a flow diagram of an example of a method for automatically cutting containers carried out according to the principles of the disclosure;

FIG. 7 illustrates a block diagram of an example of a controller constructed according to the principals of the disclosure;

FIG. 8A illustrates a front view of an example of a compliant cutting tool having a blade depth that is not variable and does not use a blade bank;

FIG. 8B illustrates a perspective view of the compliant cutting tool of FIG. 8A;

FIG. 9A illustrates a diagram of an example of a compliant cutting tool having a variable blade depth according to the principles of the disclosure;

FIG. 9B illustrates a top view of the compliant cutting tool of FIG. 9 wherein a depth of a blade is variable via a mechanical interface;

FIG. 9C illustrates a top view of a compliant cutting tool wherein an angle of a blade is variable via a mechanical interface;

FIG. 10 illustrates an example of a compliant cutting tool and a blade bank (e.g. a cartridge) for more than one blade according to the principles of the disclosure;

FIG. 11 illustrates a bottom cutaway view of the compliant cutting tool of FIG. 10 that provides additional details of an example of the interaction of a mechanical interface and a blade for varying blade depth;

FIG. 12 illustrates a perspective view of another example of a compliant cutting tool constructed according to the principles of the disclosure;

FIG. 13 illustrates a side view of the compliant cutting tool of FIG. 12 that shows a mechanical interface;

FIG. 14A illustrates a perspective view of an example of blade bank constructed according to the principles of the disclosure;

FIG. 14B illustrates a side view of a portion of the compliant cutting tool of FIG. 12 demonstrating the ejection of an active blade; and

FIG. 15 illustrates a bottom view of the compliant cutting tool of FIG. 12 illustrating the various steps from inserting a blade bank to removing the blade bank when new blades are needed.

DETAILED DESCRIPTION

Even though manually cutting containers is an option, container processing facilities often use an automated process to open containers. This automated process can optimize labor efficiencies and also eliminate risk that an operator will receive a laceration while cutting open a container. An automated process, however, can be challenging since the containers can be of various sizes and may require different types of cuts or particular cuts according to the container. For example, containers can be damaged during shipment wherein one or more sides of a container are uneven. With an uneven side, the blade used for the automated cutting could penetrate a side of the container too much and damage product within, not penetrate a side enough to make a cut through the side of the container, or both. Additionally, another consideration with an automated cutting process is that one or more sides of a container may include a hazard, which can potentially damage the blade during cutting. A hazard can be a staple or another type of metal fastener.

The disclosure provides an automated container cutting system, a compliant cutting tool, and a process for automatically cutting containers that address these concerns with automated cutting processes. The compliant cutting tool is attached to a moveable support of the automated container cutting system and includes a blade that cuts an outer surface of a container along a cut line. The cut line can be independent of a cutting path of the moveable support. For example, the cut line can be a contoured cut line along a misshapen side of a box while the cutting path of the moveable support moving the compliant cutting tool is in a straight motion. As such, the compliant cutting tool can be used to automatically cut a container having one or more non-planar sides using a moveable support that follows a straight path. The cutting path can also be a non-straight path. In some examples a controller can determine a shape of a container based on sensors and generate a cutting path based on the determined shape. One or more scanners can be used to create a point cloud of data for the controller to generate the cutting path. Controller 520 of FIG. 5 provides an example of a controller that can be used to determine the cutting path based on sensor data, such as from sensors and positioners 530.

A container as used herein is an object that can hold one or more products and be used to ship or transport the one or more products. The container can be made from a variety of durable materials, such as wood, metal, plastic, and non-durable, such as corrugated fiberboard, paperboard, and cardboard. A container has a three dimensional shape and typically a flat bottom that allows transporting on a conveyor system and stacking. A container can be, for example, a rectangular prism having flat, parallel, rectangular sides or walls. A container can have a separate lid or one or more flaps that are used to enclose the one or more products. A fastener such as an adhesive, glue, staple, or tape can be used to secure the lid or flaps. A box, such as a cardboard box, is an example of a container and will be used in parts of the disclosure as a non-limiting example of a container.

FIGS. 1-2E illustrate examples of a box with products and having sides that are planar or non-planar. A straight cut line and a contoured cut line are also shown. Regardless if a straight or contoured cut line, the cutting path of a moveable support, such as a robotic arm, moving a cutting tool for the cutting can be along a straight, linear path.

FIG. 1 illustrates a side view of an example of a box 110 having products 120. A tool path, such as for a compliant cutting tool, is represented in FIG. 1 along a side 115 of the box 110. Side 115 is also denoted in the top views (view A) of box 110 in FIGS. 2A to 2E to show examples of planar and non-planar sides, different cut lines, and different cutting paths. The cut lines and cutting paths in FIGS. 2A-2E are in the direction of the tool path as shown in FIG. 1. The cutting paths are the path of a moveable support that moves a cutting tool along the cut lines. Cutting path 210, which is the same in FIGS. 2A to 2C, is an example of a cutting path that is a straight, linear path. Cutting paths 250 and 260 of FIGS. 2D and 2E are examples of cutting paths that are not straight linear paths.

In FIG. 2A side 115 is planar and cut line 220 is a straight cut line that is parallel with cutting path 210. With side 115 being planar, a blade of a cutting tool can be moved along cut line 220 without damaging the products 120. With the straight cut line 220, the cutting tool does not need to be a compliant cutting tool.

In FIG. 2B, cut line 220 is shown again. However, in this example side 115 is non-planar and the blade of the cutting tool can damage the products 120 by following the straight cut line 220.

Side 115 is also non-planar in FIG. 2C. However, instead of straight cut line 220, a contoured cut line 230 is shown that follows the peaks and valleys of the side 115. To follow the contoured cut line 230 a compliant cutting tool as disclosed herein is used such the blade does not damage the product 120. More specifically, the compliant cutting tool includes a blade that cuts the non-planar side 115 along contoured cut line 230, which is independent of cutting path 210. FIG. 2F illustrates a compliant cutting tool following the contoured cut line 230.

FIGS. 2D and 2E illustrate cutting paths that are non-straight linear paths. Unlike cutting path 210, cutting path 250 of FIG. 2D and cutting path 260 of FIG. 2E are partially contoured (cutting path 250) and contoured (cutting path 260). As noted above a controller can determine a shape of a container based on sensors and generate a cutting path based on the determined shape. The partially contoured cutting path 250 generally follows the shape of the side 115 while contoured cutting path 260 more closely corresponds to the determined shape of the side 115. The partially contoured cutting path 250 includes a series of straight lines that are used to generally follow the shape of side 115. Even with a non-straight cutting path such as with partially contoured cutting path 250 and contoured cutting path 260, the cut line of the compliant cutting tool can still be independent of the cutting path. In other words a non-straight cutting path can also be determined by a controller and used to move the compliant cutting tool independent of the contoured cut line.

FIG. 2F illustrates compliant cutting tool 250 that compensates for the peaks and valleys of the contoured cut line 230 while being moved by moveable support 260 along the straight cutting path 210. With a cutting path that is non-linear, such as partially contoured cutting path 250 and contoured cutting path 260, the compliant cutting tool 250 would not have to compensate as much for the peaks and the valleys. In FIG. 2F, the moveable support 260 is a robotic arm that is coupled to the compliant cutting tool 250 via a pin 270 in a shaft 259 of the compliant cutting tool 250. The compliant cutting tool 250 can be coupled to the moveable support 260 via other coupling means.

Compliant cutting tool 250 includes a blade 253, which can be a razor blade. As shown in FIG. 2F, compliant cutting tool 250 is compliant in a single direction (direction of compliance) that corresponds to the direction compliant cutting tool 250 is being moved by the moveable support 260. Typically the direction of compliance is approximately perpendicular to the direction of the cutting path as shown in FIG. 2F wherein the direction of compliance is perpendicular to cutting path 210.

The cutting path 210 is illustrated with respect to a single side 115 of box 110 as an example. Cutting paths can vary depending on the type of cut desired. For example, in addition to cutting sides of a container, another example is to cut the top of a container, such as a tape cut. Another non-limiting example is a window cut on the side of a container (cutting in the horizontal direction on some cuts and in the vertical direction on other cuts). Advantageously the compliant cutting tool 250 can be used to provide safe, automated cuts of different types for deformed containers such as shown in FIGS. 2B and 2C. Deformed containers can also have a bulging top or crushed corner upon which the compliant cutting tool 250 disclosed herein can be advantageously used.

Considering corners, cutting paths can also traverse corners to provide desired cuts and prevents blades from disengaging with containers. For example, cutting path 210 can extend around a corner of container 100 and prevent the blade 253 from disengaging with the container 100 when traversing the corner. Blade 253, therefore, is engaged (or remains engaged) as the moveable support 260 moves the compliant cutting tool 250 to cut corners of the container 100.

Compliant cutting tool 250 further includes a wear plate 257, also referred to as a foot, which is configured to position the blade 253 against the outer surface of side 115 during cutting of the side 115. A holder of the compliant cutting tool, not shown in FIG. 2F, can be used to maintain at least a portion of the wear plate 257 against the outer surface of side 115 during the cutting. The holder can be, for example, one or more springs that push at least a portion of the wear plate 257 against the outer surface of side 115 during the cutting. The holder can also be another type of device that applies a force, such as a pneumatic piston. The blade 253 can be fixed such that the cutting depth and blade angle is constant during the cutting. Alternatively, the blade 253 can be repositioned during cutting. For example, the depth and angle of the blade 253 can be automatically varied during the cutting.

FIG. 3 illustrates an example of blade depth and blade angle with respect to blade 253. The depth of the blade is the distance the blade protrudes or sticks-out from the wear plate via, for example, a blade slot. The blade depth can be dynamic in that it could be programmatically adjusted depending on the characteristics of a container. Accordingly, the blade depth can be set at a certain depth and remain at the same depth while cutting a container. The blade depth can also be varied while a cut is in process. As such, the force required to make the cut may be decreased. For example, oscillating the blade quickly or slowly in a direction perpendicular to a cutting path while cutting may allow the compliant cutting tool to cut the container along the cutting path while using less force than a non-oscillating blade. This may be advantageous as it would aid in preventing the container from deforming or moving, such as tilting, during cutting. The rate of oscillation of the blade may vary from 0.01 Hz to 18 MHz. Various means can be used to oscillate the blade at a desired frequency. For example, electromagnets can be used to control the motion of the moveable support or a feature, such as a feature of a compliant cutting tool to oscillate the blade during cutting. An electric motor may also be used control movement of the blade. U.S. patent application Ser. No. 17/967,699, which is incorporated herein by reference in its entirety, includes information regarding repositioning a blade during cutting, such as via oscillating the blade.

The blade angle of the blade can also be dynamic. Similar to the blade depth, the blade angle can be varied for particular containers and set while cutting the containers and/or can be varied during cutting of containers. The blade angle is the angle between a normal line (which extends from the tangent of the wear plate 257 at the point of the blade 253) to the blade 253. The blade can be rotated, for example, around the z axis of the compliant cutting tool with respect to the wear plate to alter the blade angle. An example of the z axis is shown in FIGS. 8A, 9, 10, and 12 for the various compliance cutting tools. An electric motor can be added to the various examples of the compliance cutting tools of FIGS. 8A, 9A, 10, and 12 to provide rotation for changing the blade angle. Accordingly, a repositionable blade is disclosed wherein a position of the blade with respect to a container can be varied by changing the blade depth, the blade angle, or a combination of both. Varying the position can be done before, after, or during the cutting.

A controller of an automated container cutting system, such as shown in FIG. 5, can automatically control the blade position changes based on, for example, the physical traits of a container to be cut (dimensions, sidewall thickness, sidewall material, box construction such as folds, products or packaging inside of the box, etc.), the physical traits of the products inside of the container (product type, product height, product location within the container, packaging type, packaging location with the container, etc.), and historical data. The controller can send signals to a mechanical interface to direct repositioning of the blade. The controller can also be used to control the oscillating the blade.

FIG. 4 illustrates a block diagram of an example of compliant cutting tool 400 having at least one blade, represented by blade 410, and a blade manager 420 such as disclosed herein. The blade 410 is a repositionable blade and the blade manager 420 is configured to reposition the blade 410. Accordingly, the blade manager 420 is configured to control the blade depth and/or blade angle. The blade manager 420 can include one or more processors, represented by processor 422, to control positioning of the blade 410. The processor 422 can be, for example, a microprocessor. The blade manager 420 can receive signals (commands) from the controller to extend, retract, or rotate the blade. The controller can be, for example controller 520 of FIG. 5. The processor 422 can control a mechanical interface 424 according to the commands to cause repositioning of the blade 410. In other examples, the controller can control the mechanical interface 424 via the commands without using the processor 422. For example, the blade manager 420 may not include the processor 422 and simply be the mechanical interface 424 that is controlled by a controller that is not located on the compliant cutting tool 400. The mechanical interface 424 can include pins that engage with slots of the blade 410 and extends or retracts the blade 410 to vary the blade depth and be used with an electric motor to rotate the blade 410 to vary the blade angle.

The compliant cutting tool 400, therefore, has the features of a repositionable blade that can have a variable blade depth and/or a variable blade angle. The disclosure also provides other types of compliant cutting tools with different features or combination of features. Additional features include, for example, a fixed blade depth, fixed blade angle, quick blade exchange, and a blade bank. Compliant cutting tool 250 can include one or more of these features. The multiple different compliant cutting tools can be part of an automated container cutting system and can also be used in processes for automatically cutting containers. A non-compliant cutting tool can also include one of more of the features disclosed herein, such as a variable blade depth and/or angle, a fixed blade depth, fixed blade angle, quick blade exchange, and a blade bank.

FIG. 5 illustrates a block diagram of an example of an automated container cutting system 500 constructed according to the principles of the disclosure. The automated container cutting system 500 and automatic container cutting process can be located/performed in a container processing facility that opens containers having products and further processes the products. The containers can be received via shipment, such as by truck or rail. Examples of a container processing facility include warehouses, retail stores, wholesale stores, storage facilities, etc.

The automated container cutting system 500 includes a cutting system 510 and a controller 520. The cutting system 510 includes a compliant cutting tool 512, such as disclosed herein, and a moveable support 514 that supports and moves the compliant cutting tool 512.

The moveable support 514 is controlled by the controller 520 to move the compliant cutting tool 512. The moveable support 514 can translate, rotate, or translate and rotate the compliant cutting tool along a cutting path to cut a container. The moveable support 514 can be a robotic arm capable of moving the compliant cutting tool 512 in at least three orthogonal axes and also rotate about its axis. The moveable support 514 can also include other programmable devices for moving the compliant cutting tool 514, such as a programmable gantry arm. The controller 520 directs the moveable support 514 and the compliant cutting tool 512 to cut containers.

The controller 520 of the automated container cutting system 500 can be used to monitor one or more cutting factors for automatically determining when to replace a blade of the compliant cutting tool 512. Additionally, the controller 520 can automatically change the position (or state) of the blade for the automatic container cutting process. The controller 520 can interact with a blade manager of a compliant cutting tool for monitoring and altering a blade. For example, the compliant cutting tool 512 can be compliant cutting tool 400 and the controller 520 can interact with a blade manage 420.

The automated container cutting system 500 can also include various sensors and positioners, represented by sensors and positioners 530, which are communicatively coupled to the controller 520. The sensors and positioners 530 can be conventional devices that obtain data and provide the data to the controller 520 for performing different functions. For example, the automated container cutting system 500 can automatically cut containers of various sizes and the physical traits of the containers can be determined by the system 500. One or more sensors can be used as a dimensioning device configured to determine at least some of the physical traits or attributes of the containers before or during cutting. The dimensioning device can be a scanner that reads an identifier on the containers and allows the controller 520, via a database lookup, to determine the physical traits of the containers. The scanner and identifier, for example, can be a barcode scanner and a barcode. A SKU is another example of an identifier that can be used. Other types of sensors can be used to determine one or more physical traits of containers, such as laser sensors, cameras, other types of scanners, etc. A combination of different sensors can be used to obtain the physical traits. The one or more sensors may or may not operate to determine the physical traits while the container is moving on the transport system. The physical traits can also be provided as an input from an operator to the system when, for example, using a single container size. The controller 520 can receive the physical traits and use for determining one or more of the cutting path, the blade angle, the blade depth, and blade oscillations.

The automated container cutting system 500 can also include a transport system 540. The transport system 540, such as a conveyor, can include actuatable rollers and may include two or more separately operable zones. The transport system 540 can connect to or be part of a transport system of an automated decanting system, wherein the automated container cutting system 500 is part of, for example a station, of the automated decanting system. An example of an automated decanting system is provided in U.S. patent application Ser. No. 18/605,388, which is incorporated herein by reference in its entirety.

The controller 520 can cooperate with the sensors and positioners 530 to direct operation of the transport system 540, such as controlling rails to position containers within a cutting zone for the cutting. For example, the controller 520 can operate a stopping rail 550 to stop a container in the cutting zone on the transport system 540 that corresponds to the cutting system 510. Once the container is in the cutting zone, the controller 520 can also operate a positioning rail 554 to hold the container in the cutting zone against a rail of the transport system 540. The positioning rail 554 can start operating (e.g. contacting and/or snugging the container) while the container is still moving. The stopping rail 550 and the positioning rail 554 cooperate to hold the container when cutting the container sides. One or more of the stopping rail 550 and the positioning rail 554 can include a clamp 558 that holds or at least assists in holding the base of the container during the cutting. The clamp 558 can be constructed of a material that “grabs” the container, such as rubber or another similar material.

The clamp 558 can be a bar that runs along at least part of the length of a rail at a position at or proximate to the bottom of the rail to press against the side of the container close to or at the bottom of the container. For example, the clamp 558 can be attached to or be part of a rail at a position that corresponds to the intersection of the bottom surface of the container and the container side against the rail. The clamp 558 can be constructed of a strip of rubber or another material with gripping properties that is attached to a base, such as a piece of sheet metal. The rubber/base assembly can then be attached to one of more of the rails, such as the stop or positioning rails 550 or 554, to provide clamping force to the container during cutting. The rubber can be attached to the base and the rubber/base assembly can be attached to one or more of the rails via a chemical connection, mechanical connection, or a combination thereof. For example, a glue or another type of adhesive, screws, rivets, etc., can be used. The clamp 558 can be attached to one or more rails or can be formed as part of one or more rails. When attached, a non-permanent connection can be used to allow replacement due to wear. Instead of a rail, the clamp 558 can be part of or added to another device, such as a moveable arm, that is directed by the controller to hold a container when being cut.

FIG. 6 illustrates a flow diagram of an example of a method 600 for automatically cutting containers carried out according to the principles of the disclosure. A compliant cutting tool as disclosed herein can be used for the cutting. As discussed above regarding FIGS. 1 to 2D, the compliance can be along a width and a length of a container. The compliance can also be along a height of the containers such that the blade of the compliant cutting tool remains at a desired depth from a top of a container.

The containers can be part of a delivery to a container processing facility having an automated container cutting system such as disclosed herein and represented as an example in FIG. 5. One or more of the steps of method 600 can be performed by an automated container cutting system. For example, a controller, such as controller 520, of the automated container cutting system, such as one or more processors thereof (including a programmable logic controller (PLC)), can be configured to perform some of the operations of method 600 according to one or more algorithms. Method 600 starts in step 605.

In step 610, containers having products are received. The containers can be received via one or more transport systems and delivered to the automated container cutting system. One or more conveyors or other transport systems can be extended from the delivery vehicle to the automated container cutting system.

In step 620, physical traits or attributes of the containers are obtained. A dimensioning device can be used to obtain the physical traits of the containers. The physical traits can also be provided as an operator provided input when, for example, using a single container size. The physical traits include dimensions of the containers, such as at least two orthogonal dimensions. The physical traits can be used to determine a cutting path for the compliance cutting tool and also used to maintain a cut line along a surface and maintain a certain cutting depth on the surface with the compliance.

Cutting parameters are determined in step 630 using at least some of the physical traits. User preferences or other input data provided by a user can also be used to determine the cutting parameters. The input data can include information regarding the product and product packing within the containers. For example, liquids, solids, metal cans, plastic bags, etc. Such input information can also be determined via the dimensioning device. The cutting parameters include the cutting path and blade settings, which can vary during cutting or be fixed during cutting. The cutting parameters can also include a force to use for the cutting, if oscillating of the blade will be used, and how to react, e.g., stop cutting or jump around the hazard and the distance to jump, when detecting a hazard if a hazard sensor is present. The force can be a minimum force needed to move (e.g., extend or retract) the blade through the container. The controller of the automated container cutting system can be configured to determine the cutting parameters.

In step 640, a compliant cutting tool is used to perform the cutting based on the determined cutting parameters. The different types of compliant cutting tools disclosed here can be used in step 640. A moveable support can be instructed to move the compliant cutting tool along the determined cutting path. The determined blade settings can also be set/controlled for the cutting process. The controller can send commands to the compliant cutting tool and the moveable support to perform the cutting according to the cutting parameters.

In step 650, a determination is made if the blade of the compliant cutting tool needs to be replaced. As noted above this determination can be based on one or more cutting factors. The controller can make the determination. If replacement is needed, the blade can be automatically replaced with another blade from a blade bank or blade bank that is integrated with the compliant cutting tool. The method 600 can then continue to step 660 with the automatic cutting of containers. If replacement is not needed, the method will also continue to step 660. The method 600 can continue for a set amount of time, set amount of containers, or as long as containers are delivered to the automated container cutting system. The method 600 ends in step 670. The ability to change blades and a blade bank as noted in step 650 can also be used with a cutting tool that is non-compliant. As such, a compliant cutting tool and a non-compliant cutting tool can include a blade bank.

FIG. 7 illustrates a block diagram of an example of a controller 700 constructed according to the principals of the disclosure, such as controller 520 of FIG. 5. The controller 700 includes one or more processors, represented by processor 710, which are configured to direct the operation of the controller 700 to control the operation of an automated container cutting system, such as illustrated in FIG. 5. The processor 710 may be a conventional processor such as a microprocessor or a PLC. Additionally, the controller 700 includes one or more interfaces, represented by interface 720, and one or more memories, represented by memory 730, coupled thereto. The components of the controller 700 can be coupled together by and communicate via typical means used in the industry, such as conventional connections and communication protocols. One skilled in the art will understand that the controller 700 can include additional components typically included with a controller such as a power supply or power port.

The interface 720 includes multiple ports for transmitting and receiving data to and from components of the automated container cutting system 100. For example, data representing box dimensions can be received from dimensioning devices. The interface 720 can support wireless or wired communications. Additionally, the interface 720 can receive programming to direct the operation of the automated container cutting system. The programming instructions can be code representing algorithms that, for example, determine a cutting path and blade settings, such as blade depth, blade angle, and generate commands based thereon to instruct a compliant cutting tool and a moveable support to cut a container. The commands can also be based on physical traits of the container, user inputs and user preferences. The commands can also direct a transport system to move the container into and out of a cutting zone by, for example, receiving sensors inputs and controlling one or more rails, such a stop rails. The programming instructions can be encrypted for security.

The memory 730 is constructed to store data and computer programs. The memory 730 can be a conventional memory or data storage. The memory 730 may be a non-transitory computer readable medium configured to store operating instructions, such as the programming instructions, to direct the operation of the processor 710 when initiated thereby. The operating instructions may correspond to one or more algorithms that provide the functionality of the operating schemes disclosed herein. The memory 730, therefore, stores the programming instructions that direct the operation of an automated container cutting system, such as disclosed herein. The memory 730 can also store data on different containers, including dimensions, thickness of sides, material, and shape. The processor 710 can use this data to determine the commands for instructing the compliant cutting tool. The instructions can include a force needed to make the cut based on, for example, the material, the thickness, or a combination thereof. The processor 710 can also generate commands to work with other components of a decanting system. The commands can correspond to one or more steps of method 600.

In contrast to compliant cutting tool 400, FIGS. 8A and 8B illustrate different views of an example of a compliant cutting tool 800 wherein the blade depth is not variable and a quick blade exchange is not available. FIG. 8A illustrates a front view and FIG. 8B illustrates a perspective view. Compliant cutting tool 800 includes coupler 810, a sliding mechanism 820, a wear plate 830, a blade slot 840, and a holder 850 that is visible in FIG. 8B.

The coupler 810 is configured to connect to a moveable support that is used to move the compliant cutting tool 800 along a cutting path. The configuration of the coupler can vary depending on the type of moveable support that is used. Coupler 810 is an example of a coupler configured to couple to a robotic arm, such as a robotic tool changer.

The sliding mechanism 820 is configured to allow movement of the compliant cutting tool 800 along the axis of the direction of compliance while being moved along the cutting path by the moveable support. The compliant cutting tool 800 can slide back and forth along the direction of compliance axis while moving along a contoured cut line, such as contoured cut line 230.

The wear plate 830 is configured to position a blade (not shown) of the compliant cutting tool 800 against an outer side surface of a container during cutting. The blade extends through the blade slot 840 and the holder 850 maintains at least a portion of the wear plate 830 against the outer side surface of a container during the cutting. As illustrated in FIG. 8B, the holder 850 can be a spring that pushes at least a portion of the wear plate 830 against the outer side surface during the cutting and provides a force along the direction of compliance axis for back and forth movement of the compliant cutting tool 800 via the sliding mechanism 820.

The compliant cutting tool 800 includes a single blade. The blade can be a utility razor blade having slots on the opposite side of the cutting edge that are used to secure the blade for cutting. The single blade can be stored in a blade bank section of the compliant cutting tool 800 located behind, under, above, or within the wear plate 830. FIG. 9A provides an example of another compliant cutting tool that does not include storage for multiple blades but does allow variable blade depth and angle.

FIG. 9A illustrates an example of a compliant cutting tool 900 wherein a blade depth is variable. Features similar to those identified in FIGS. 8A and 8B are identified in FIG. 9A using the same element numbers. In FIG. 9A, blade 901 is also shown.

Varying the depth of blade 901 can be via a mechanical interface 910. For example, rotation of a gear 914 of the mechanical interface 910 can be controlled via a drive shaft 920 to vary the blade depth by rotating gear 916 of the mechanical interface 910. At least one pin, protrusion, or another feature can be located on gear 916, or on a lever or disc connected to gear 916, to engage one or more slots of blade 901 while the gear 914 moves along a circular path. The blade 901 can be retained, such as via one or more stationary pins, such that the circular movement of the gear 914 provides linear movement of the blade 901 out of the blade slot 840. The at least one pin or other feature can remain engaged with the slot or slots to allow increasing and decreasing of the blade depth.

The drive shaft 920 can be controlled by, for example, a processor of the compliant cutting tool 900, a controller of an automated container cutting system, or a combination thereof. Processor 422 and controller 520 are examples of a processor and controller that can be used. The drive shaft 920 can be a flexible drive shaft.

FIG. 9B illustrates a top view of the compliant cutting tool 900 wherein a depth of the blade 901 is variable via the mechanical interface 910. The angle of a blade can also be varied. FIG. 9C illustrates a top view of compliant cutting tool 950 that is configured to vary the angle of the blade 901. For example, rotation of a gear 954 of mechanical interface 960 can be controlled via a drive shaft, such as drive shaft 920, to vary the blade angle by rotating gear 966 of the mechanical interface 960. At least one pin, protrusion, or another feature can be located on gear 966, or on a lever or disc connected to gear 966, to engage one or more slots of blade 901 while the gear 964 moves along a circular path around the z axis of the compliant cutting tool with respect to the wear plate to alter the blade angle. The blade 901 can be rotated against a pin, such as a stationary pin, such that the rotation of the gear 964 provides a change of the angle of the blade 901 out of the blade slot 840. In some examples, mechanical interface 910 can be configured to also provide rotation for changing a blade angle. For example, a pin used for angle rotation can be retractable and not used for blade depth changes but then used for blade angle changes. An electric motor can be used to rotate the mechanical interfaces 910 and/or 960 to change blade depth, blade angle, or both. Another means can also be used for changing blade depth and blade angle. As with FIG. 9A, features similar to those identified in FIGS. 8A and 8B and other figures are identified in FIGS. 9B and 9C using the same element numbers.

It is understood by those in the art that using the principles of this disclosure, multiple blades could be present within the compliant tool in order to achieve blade compliance in multiple directions or planes. For the sake of example, this disclosure refers to the cutting tool as using a single blade cutting along the length and width of the container as shown in FIGS. 1 to 2E. It is conceivable that the complaint cutting tool could have cutting compliance along the length, width, and/or height of the container and any combination of length, width, and height compliance. The compliant cutting tool can use a single blade for cutting containers and can also be configured with the ability to replace the blade from a bank of blades from blade bank attached to or built into the compliant cutting tool. The single blade can be removed by pulling, pushing, or dropping the single blade from the compliant cutting tool using features within the compliant tool without the need of operator interacting with the blade. The new blade can then be moved into place via, for example, a spring located in the blade bank.

Replacing the blade can be done automatically based on one or more cutting factors that impact the wear of the blade. Such cutting factors include, for example, number of containers cuts, total distance cut, type of cuts, material being cut, hazards encountered during cuts, an increase of force needed for cuts, operator preferences, type of blade, etc. Each of the one or more factors or a combination thereof can have a pre-defined target that is used to determine when to replace a blade. For example, after cutting 300 cardboard boxes the blade is replaced. Actual wear can be used to determine when to replace a blade. For example, a camera can be used to monitor the condition of the blade and based on visual comparison determine when a blade needs to be replaced. Alternatively, the force needed to cut the cardboard may be measured and when the force reaches an upper threshold the blade needs to be replaced. Actual wear may be considered as one of multiple factors to determine when to replace a blade or used solely to determine when to replace. The cutting factors may be weighted. With automatic replacement, the cutting tool could be used longer without having to service the cutting tool and replace a blade. To reduce damage to blades and possibly extend the time before a replacement blade is required, the compliant cutting tool can include a hazard sensor that automatically senses when a hazard is present along a cut line and automatically evades the hazard, such as by stopping the cutting or jumping over/around the hazard.

FIG. 10 illustrates an example of a compliant cutting tool 1000 that includes blade bank 1010 (e.g. a cartridge) for more than one blade. The blade bank 1010 can be a cartridge that includes a spring, such as a leaf spring, that advances the blades in the blade bank 1010 when one is removed. For example, when an active blade is removed, such as blade 901, the stack of blades in the blade bank 1010 shift down and can then be slid into cutting position. Blades can loaded into the blade bank 1010 one at a time by pushing against the stack of blades and sliding in another blade. The blade bank 1010 can be purchased as a preloaded cartridge of blades or blades could be loaded into the cartridge at the job site. The blade bank 1010 can be disposable. For example, the structure of the blade bank 1010 can be constructed of plastic (for example, ABS, polycarbonate, or Delrin) or metal (for example, steel, stainless steel, or aluminum) or another similar material that is sufficiently rigid to protect the blades and allow automatic changing of the blades.

The blade bank 1010 can be used for automatically replacing blades, such as blade 901. The replacement can be based on one or more cutting factors, such as those noted above. In addition to being used to change the blade depth and/or blade angle, the mechanical interface 910 can also be used to eject blade 901 for automatic replacement using the next blade in the blade bank 1010. FIG. 11 illustrates a bottom cutaway view of compliant cutting tool 1000 that provides additional details of an example of the interaction of the mechanical interface 910 and the blade 901 for ejection. Blade bank 1010 is not visible in FIG. 11. As gear 916 rotates, pins 917 engage with slots 903 of blade 901. As described with FIG. 9A, the rotation of gear 916 and the interaction of the pins 917 and the slots 903 can be used to change the depth of the blade 901. For such changes, at least one of the pins 917 can remain engaged with one of the slots 903. Further rotation of the gear 916 can also be used to eject blade 901 via a pusher arm 918 connected to or integrated with gear 916. Pusher arm 918 includes a rounded end 919 that is positioned to engage with an angled side of the blade to push blade 901 out of the blade slot 840. One of the pins 917 can remain engaged with one of the slots 903 as pusher arm 918 moves the blade 901 out of the blade slot 830. As the pins 917 disengage with the slots 903 during rotation of gear 916, the pusher arm 918 can push blade 901 out. Depending on how blade 901 will be removed, the pusher arm 918 can partially push blade 901 out of the blade slot 840 or completely eject blade 901 out of the blade slot 840. For partial ejections, a device external to the compliant cutting tool 1000 can grip the partially ejected blade for removal while a moveable support moves the compliant cutting tool 1000 away. Accordingly, the blade can be automatically ejected partially or completely.

After ejection of the blade 901, gear 916 can rotate pins 917 to engage with slots of the next blade in blade bank 1010. In FIG. 11, two pins 917 are shown. Additional pins may also be connected to or integrated with gear 916 and gear 916 can be rotated such that the other pins or set of two pins engage with slots of the next blade.

FIG. 12 illustrates a perspective view of another example of a compliant cutting tool 1200 constructed according to the principles of the disclosure. Similar to compliant cutting tool 1000 compliant cutting tool 1200 is also configured to provide variable blade depth. Compliant cutting tool 1200 includes a coupler 1210, a sliding mechanism 1220, a wear plate 1230, a blade slot 1240, a holder 1250, and blade bank 1260, which are each configured to perform as the coupler 810, the sliding mechanism 820, the wear plate 830, the blade slot 1240, the holder 850, and blade bank 1010 of compliant cutting tool 1000. The compliant cutting tool 1200 also includes an electrical connector 1270 configured to connect to a controller, such as controller 520, to direct operations thereof. The compliant cutting tool 1200 also includes a mechanical interface 1280 that is not visible in FIG. 12 but is in FIG. 13. The mechanical interface 1280 or another similar mechanical interface can be used to vary blade angle such as disclosed in FIG. 9C.

FIG. 13 illustrates a side view of compliant cutting tool 1200 that shows mechanical interface 1280. As with mechanical interface 910, mechanical interface 1280 also includes two gears, 1284 and 1286, which are configured to vary the depth of a blade (not shown in FIGS. 12-13). Gear 1286 is rotated by gear 1284, which receives control signals via the connection 1270. Similar to gear 916, rotation of gear 1286 causes movement of features that move the active blade in blade bank 1260 along the direction of compliance axis by engaging in slots of the blade. FIG. 14A illustrates an exploded view of an example of blade bank 1260 that is loaded with blades 1401.

In the example of FIG. 14A, blade bank 1260 includes a top plate 1410, a bottom plate 1420, a retention clip 1430, and a stack spring 1440. The top plate 1410 and the bottom plate 1420 are connected together and define a volume where the blades 1401 are stored. The top plate 1410 includes a stack retainer 1412 that is configured to physically constrain the blades 1401 in position within the blade bank 1260 against the force of the stack spring 1440. The stack spring 1440 is positioned on the bottom plate 1420 and pushes up against the blades 1401. The stack spring 1440 maintains pressure against the blades 1441 and pushes a next blade up for use when an active blade of the blades 1401 is ejected. When loading the blades 1401, the stack spring 1440 is depressed and the blades 1401 are inserted. The blades 1401 can be loaded one at a time.

The stack retainer 1412 is also configured to position the blades 1401 in the correct position, including height, to enable interaction with carriage forks of a compliant cutting tool, such as carriage forks 1512 of FIG. 15. Additionally, the stack retainer 1412 is configured to provide a point of contact with the active blade during operation to keep the active blade secure while cutting. As the active blade is being ejected, the stack retainer 1412 loses contact.

The bottom plate 1420 is configured to provide a support for the blades 1401 and the stack spring 1440. The bottom plate 1420 also includes alignment holes 1422 that are configured to align with pins, such as alignment pins 1505 of FIG. 15. A screw 1450 extends through the bottom plate 1420 and is used to secure the blade bank 1260 to the compliant cutting tool via a tapped hole thereof.

The retention clip 1430 is configured to align the blades 1401 and keep the blades secure during transit using a protrusion 1432 that extends into a first slot of the blades 1401. The retention clip 1430 also prevents or at least reduces jamming when loading the blades 1401 and provides protection against the sharp edge of the blades 1401.

The retention clip 1430 includes a dog leg 1434 that is moved when the blade bank 1260 is being connected to the compliant cutting tool and pivots the retention clip 1430 at a pivot point 1436 away from the stored blades 1401 such that the protrusion 1432 is removed from the first slot and the retention clip 1430 is no longer holding the blades 1401. A release pin 1520 identified in Step 2 of FIG. 15 activates the dog leg 1434 to release the retention clip 1430.

Once connected a pier of the compliant cutting tool is located in slot 2 of the blades 1401. The pier, such as pier 1522 identified in Step 2 of FIG. 15, is configured to secure the blades 1401 when the blade bank 1260 except for the active blade. In other words, the height of pier 1522 extends up to the active blade but does not protrude into slot 2 of the active blade, which allows movement of the active blade. The top of pier 1522 also provide a contact point to the active blade.

In addition to the stack retainer 1412, the top plate 1410 also includes a captivation rail 1414 that provides a contact point for the active blade that assists in preventing translation and rotation of the active blade during cutting. At the end of the captivation rail 1414 is an end point 1416 that has a rounded face that provide a last contact point of an active blade when being ejected. The rounded or chamfered face allows the free release of the active blade when being ejected by providing a pivot point allowing the ejected blade to fall away due to gravity. FIG. 14B illustrates a side view of a portion of compliant cutting tool 1200 demonstrating the ejection of the active blade. In FIG. 14B the blade bank 1260 is connected to the compliant cutting tool 1200. A blade bank can also be used with a cutting tool that is not compliant wherein blades can be similarly replaced. As such, automatic replacement of blades can be used with compliant and non-compliant cutting tools.

FIG. 15 illustrates a bottom view of compliant cutting tool 1200 illustrating the various steps from inserting blade bank 1260 to removing blade bank 1260 when new blades are needed. Components denoted in FIGS. 12-14 are similarly denoted in FIG. 15. Additionally, components of the compliant cutting tool 1200 that are visible from the bottom view are identified in FIG. 15, such as moving mechanism 1510. The moving mechanism 1510 is moved linearly along the direction of compliance axis due to rotation of the gear 1286. Gear 1284, not visible in FIG. 15, is connected to the shaft of a motor, such as an electric motor. The controller, such as controller 520, activates the motor and causes gear 1284 to spin, which rotates gear 1286 clockwise or counterclockwise. Gear 1286 is connected to a worm wheel shaft, identified in Step 2 as shaft 1501, which linearly positions carriage forks 1512 of the moving mechanism 1510 within the first and second slots of the blades 1401 during the various Steps of FIG. 15. The shaft 1501 is located under plate 1503.

In Step 1, the blade bank 1260 and the compliant cutting tool 1200 are shown before being removably connected together. The alignment holes 1422 (not visible) of the blade bank 1260 are aligned with the pins 1505 of the compliant cutting tool 1200 for connection via a mechanical coupler, such as screw 1450.

In Step 2, the blade bank 1260 is connected to the compliance cutting tool 1200. Step 2 illustrates the “home” position of the blade bank 1260 being correctly seated into the compliant cutting tool 1200 tool but the blades 1401 are not engaged with the moving mechanism 1510. In other words, the carriage forks 1512 of the moving mechanism 1510 are not engaged with the slots of the top one of the blades 1401.

The carriage forks 1512 have a lead-in that pushes the blades 1401 down against the stack spring 1440 as the blade bank 1260 is pushed into place. Step 2 also demonstrates the release of the retention clip 1430 as it is pushed in and secured due to the release pin 1520 moving the dog leg 1434 when the blade bank 1260 is moved into place.

In Step 3, the moving mechanism 1510 is moved until the carriage forks 1512 engage with the slots of the top one of the blades 1401. Sensor readings, such as resistance, can be obtained and compared to predetermined thresholds to determine if the carriage forks 1512 are in the proper location for engagement with the slots. A linear potentiometer is an example of a device that can be used to provide feedback of the position of the moving mechanism 1510 and therefore the carriage forks 1512. A linear potentiometer 1507 is shown in Step 3 under the plate 1503.

In Step 3, the carriage forks 1512 engage with the slots of the blades 1401 to pick a new blade off of the blade stack 1401, move that blade to specific depths for cutting, and to induce the blade ejection process when the active blade is spent. The moving mechanism 1510 also includes a hold arm 1514 that advantageously restrains the stack of blades 1401 from moving and interfering with the carriage forks 1512 until they have travelled back over the stack of blades 1401 to engage with the top from the stored stack of blades 1401. This engagement position is referred to as the pick-up position wherein movement of the active blade can now occur in response to movement of the moving mechanism 1510.

In Step 4, the active blade is moved to a desired cut position. The desired cut position can be a particular blade depth, such as a minimum cutting depth as represented in Step 4. Step 5 indicates another cut position, a maximum cut position, which provides an example of a maximum cutting depth in which the active blade can be moved. The minimum and maximum cutting depths can be predetermined and correspond to a particular sensor reading, such as resistivity measurements from the linear potentiometer 1507. More than two blade depths can be predetermined and used. The number of blade depths can be a continuous spectrum. In both Steps 4 and 5 the carriage forks 1512 are engaged with the active blade in the cutting position.

When in a cutting position, there are five main contact points that restrain the active blade during cutting, wherein two are on top of the active blade and three are on the bottom of the active blade. The three bottom contact points are denoted in Step 4 as the holder arm 1412, the captivation rail 1414 and end point 1416 of the captivation rail 1414, and the fixed forks 1508 of the compliant cutting tool 1200.

Step 6 illustrates when the active blade has been ejected and a new blade is ready to be inserted. When the active blade is moved to the eject position, two of the three of the bottom restraints are lost (the holder arm 1412 and the fixed forks 1508) and the ejected blade pivots away from the one remaining contact point, the end point 1416. For ejection of the active blade, the carriage forks 1512 align with the fixed forks 1508 providing a path for the ejected blade to fall away. To assist with the ejection, a spring plunger 1509 is used. The spring plunger 1509 has a very shallow lead such that the linear movement of the active blade over and past it will push the spring plunger down and load it. Then, when the carriage forks 1512 overlap with the fixed forks 1508 during blade ejection, the spring plunger 1509 instantaneously releases its energy to fling the ejected blade downward out of the compliant cutting tool 1200. During ejection, the ejected blade will pivot on and away from the last remaining retention element—end point 1416. Sensor measurements can be used to determine when a blade has been ejected. A controller, such as control 520, can use the sensor measurements to position the moving mechanism 1510 to engage with the next one of the blades 1401.

More specifically, the hold arm 1514 restrains the spring loaded blades 1401 after the ejection of the active blade so that there is clearance for the carriage forks 1512 to travel back over the remaining ones of the blades 1401 without jamming on the remaining blade stack as it moves to pick up another one of the blades. Once the carriage forks 1512 are past the leading edge of the blades 1401, the hold arm 1514 will then clear the rear edge of the remaining stack of blades 1401, wherein the carriage forks 1512 are now solely holding back the remaining ones of the blades 1401 until the carriage forks are moved into the slots of the blades 1401 and the now unrestrained spring force from the stack spring 1440 pushes a new blade into place for engagement with the carriage forks 1512.

Step 7 indicates when the blade bank 1260 is empty. In such a situation, the moving mechanism 1510 is moved back into a neutral position as in Step 2. A sensor measurement can also indicate when the blade bank 1260 is empty or almost empty and generate a signal that can then be sent to the controller via the connection 1270 to indicate a loaded blade bank is needed. In Step 8, the empty blade bank 1260 is removed and the compliant cutting tool 1200 is ready to receive a loaded blade bank.

Various compliant cutting tools have been disclosed herein. For example, one compliant cutting tool can have the ability to automatically change blades but without the ability to reposition the blade. Additionally, a non-compliant cutting tool, which cannot follow the deformed sides of a container, can also have the ability to automatically change blades. Another compliant cutting tool can have the ability to automatically reposition the blade but not the ability to automatically replace blades.

A portion of the above-described apparatus, systems or methods may be embodied in or performed by various analog or digital data processors, wherein the processors are programmed or store executable programs of sequences of software instructions to perform one or more of the steps of the methods. A processor may be, for example, a programmable logic device such as a programmable array logic (PAL), a generic array logic (GAL), a field programmable gate arrays (FPGA), or another type of computer processing device (CPD). The software instructions of such programs may represent algorithms and be encoded in machine-executable form on non-transitory digital data storage media, e.g., magnetic or optical disks, random-access memory (RAM), magnetic hard disks, flash memories, and/or read-only memory (ROM), to enable various types of digital data processors or computers to perform one, multiple or all of the steps of one or more of the above-described methods, or functions, systems or apparatuses described herein.

Portions of disclosed examples or embodiments may relate to computer storage products with a non-transitory computer-readable medium that have program code thereon for performing various computer-implemented operations that embody a part of an apparatus, device or carry out the steps of a method set forth herein. Non-transitory used herein refers to all computer-readable media except for transitory, propagating signals. Examples of non-transitory computer-readable media include but are not limited to: magnetic media such as hard disks, floppy disks, and magnetic tape; optical media such as CD-ROM disks; magneto-optical media such as floppy disks; and hardware devices that are specially configured to store and execute program code, such as ROM and RAM devices. Configured or configured to means, for example, designed, constructed, or programmed, with the necessary logic and/or features for performing a task or tasks. A configured device, therefore, is capable of performing the task or tasks. Examples of program code include both machine code, such as produced by a compiler, and files containing higher level code that may be executed by the computer using an interpreter.

In interpreting the disclosure, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.

Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.

Each of the below independent claims can have one or more of the features of the dependent claims in combination.