Automated Container Cutting Apparatus, a System Including the Apparatus, and a Method of Cutting a Container

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.

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.

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.

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.

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. Controllerofprovides an example of a controller that can be used to determine the cutting path based on sensor data, such as from sensors and positioners.

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.

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.

illustrates a side view of an example of a boxhaving products. A tool path, such as for a compliant cutting tool, is represented inalong a sideof the box. Sideis also denoted in the top views (view A) of boxinto show examples of planar and non-planar sides, different cut lines, and different cutting paths. The cut lines and cutting paths inare in the direction of the tool path as shown in. The cutting paths are the path of a moveable support that moves a cutting tool along the cut lines. Cutting path, which is the same in, is an example of a cutting path that is a straight, linear path. Cutting pathsandofare examples of cutting paths that are not straight linear paths.

Insideis planar and cut lineis a straight cut line that is parallel with cutting path. With sidebeing planar, a blade of a cutting tool can be moved along cut linewithout damaging the products. With the straight cut line, the cutting tool does not need to be a compliant cutting tool.

In, cut lineis shown again. However, in this example sideis non-planar and the blade of the cutting tool can damage the productsby following the straight cut line.

Sideis also non-planar in. However, instead of straight cut line, a contoured cut lineis shown that follows the peaks and valleys of the side. To follow the contoured cut linea compliant cutting tool as disclosed herein is used such the blade does not damage the product. More specifically, the compliant cutting tool includes a blade that cuts the non-planar sidealong contoured cut line, which is independent of cutting path.illustrates a compliant cutting tool following the contoured cut line.

illustrate cutting paths that are non-straight linear paths. Unlike cutting path, cutting pathofand cutting pathofare partially contoured (cutting path) and contoured (cutting path). 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 pathgenerally follows the shape of the sidewhile contoured cutting pathmore closely corresponds to the determined shape of the side. The partially contoured cutting pathincludes a series of straight lines that are used to generally follow the shape of side. Even with a non-straight cutting path such as with partially contoured cutting pathand contoured cutting path, 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.

illustrates compliant cutting toolthat compensates for the peaks and valleys of the contoured cut linewhile being moved by moveable supportalong the straight cutting path. With a cutting path that is non-linear, such as partially contoured cutting pathand contoured cutting path, the compliant cutting toolwould not have to compensate as much for the peaks and the valleys. In, the moveable supportis a robotic arm that is coupled to the compliant cutting toolvia a pinin a shaftof the compliant cutting tool. The compliant cutting toolcan be coupled to the moveable supportvia other coupling means.

Compliant cutting toolincludes a blade, which can be a razor blade. As shown in, compliant cutting toolis compliant in a single direction (direction of compliance) that corresponds to the direction compliant cutting toolis being moved by the moveable support. Typically the direction of compliance is approximately perpendicular to the direction of the cutting path as shown inwherein the direction of compliance is perpendicular to cutting path.

The cutting pathis illustrated with respect to a single sideof boxas 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 toolcan be used to provide safe, automated cuts of different types for deformed containers such as shown in. Deformed containers can also have a bulging top or crushed corner upon which the compliant cutting tooldisclosed 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 pathcan extend around a corner of containerand prevent the bladefrom disengaging with the containerwhen traversing the corner. Blade, therefore, is engaged (or remains engaged) as the moveable supportmoves the compliant cutting toolto cut corners of the container.

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

illustrates an example of blade depth and blade angle with respect to blade. 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 plateat the point of the blade) to the blade. 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 infor the various compliance cutting tools. An electric motor can be added to the various examples of the compliance cutting tools ofto 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, 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.

illustrates a block diagram of an example of compliant cutting toolhaving at least one blade, represented by blade, and a blade managersuch as disclosed herein. The bladeis a repositionable blade and the blade manageris configured to reposition the blade. Accordingly, the blade manageris configured to control the blade depth and/or blade angle. The blade managercan include one or more processors, represented by processor, to control positioning of the blade. The processorcan be, for example, a microprocessor. The blade managercan receive signals (commands) from the controller to extend, retract, or rotate the blade. The controller can be, for example controllerof. The processorcan control a mechanical interfaceaccording to the commands to cause repositioning of the blade. In other examples, the controller can control the mechanical interfacevia the commands without using the processor. For example, the blade managermay not include the processorand simply be the mechanical interfacethat is controlled by a controller that is not located on the compliant cutting tool. The mechanical interfacecan include pins that engage with slots of the bladeand extends or retracts the bladeto vary the blade depth and be used with an electric motor to rotate the bladeto vary the blade angle.

The compliant cutting tool, 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 toolcan 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.

illustrates a block diagram of an example of an automated container cutting systemconstructed according to the principles of the disclosure. The automated container cutting systemand 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 systemincludes a cutting systemand a controller. The cutting systemincludes a compliant cutting tool, such as disclosed herein, and a moveable supportthat supports and moves the compliant cutting tool.

The moveable supportis controlled by the controllerto move the compliant cutting tool. The moveable supportcan translate, rotate, or translate and rotate the compliant cutting tool along a cutting path to cut a container. The moveable supportcan be a robotic arm capable of moving the compliant cutting toolin at least three orthogonal axes and also rotate about its axis. The moveable supportcan also include other programmable devices for moving the compliant cutting tool, such as a programmable gantry arm. The controllerdirects the moveable supportand the compliant cutting toolto cut containers.

The controllerof the automated container cutting systemcan be used to monitor one or more cutting factors for automatically determining when to replace a blade of the compliant cutting tool. Additionally, the controllercan automatically change the position (or state) of the blade for the automatic container cutting process. The controllercan interact with a blade manager of a compliant cutting tool for monitoring and altering a blade. For example, the compliant cutting toolcan be compliant cutting tooland the controllercan interact with a blade manage.

The automated container cutting systemcan also include various sensors and positioners, represented by sensors and positioners, which are communicatively coupled to the controller. The sensors and positionerscan be conventional devices that obtain data and provide the data to the controllerfor performing different functions. For example, the automated container cutting systemcan automatically cut containers of various sizes and the physical traits of the containers can be determined by the system. 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, 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 controllercan 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 systemcan also include a transport system. The transport system, such as a conveyor, can include actuatable rollers and may include two or more separately operable zones. The transport systemcan connect to or be part of a transport system of an automated decanting system, wherein the automated container cutting systemis 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 controllercan cooperate with the sensors and positionersto direct operation of the transport system, such as controlling rails to position containers within a cutting zone for the cutting. For example, the controllercan operate a stopping railto stop a container in the cutting zone on the transport systemthat corresponds to the cutting system. Once the container is in the cutting zone, the controllercan also operate a positioning railto hold the container in the cutting zone against a rail of the transport system. The positioning railcan start operating (e.g. contacting and/or snugging the container) while the container is still moving. The stopping railand the positioning railcooperate to hold the container when cutting the container sides. One or more of the stopping railand the positioning railcan include a clampthat holds or at least assists in holding the base of the container during the cutting. The clampcan be constructed of a material that “grabs” the container, such as rubber or another similar material.

The clampcan 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 clampcan 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 clampcan 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 railsor, 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 clampcan 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 clampcan 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.

illustrates a flow diagram of an example of a methodfor 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, 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. One or more of the steps of methodcan be performed by an automated container cutting system. For example, a controller, such as controller, 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 methodaccording to one or more algorithms. Methodstarts in step.

In step, 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, 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 stepusing 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, 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. 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, 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 methodcan then continue to stepwith the automatic cutting of containers. If replacement is not needed, the method will also continue to step. The methodcan 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 methodends in step. The ability to change blades and a blade bank as noted in stepcan 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.

illustrates a block diagram of an example of a controllerconstructed according to the principals of the disclosure, such as controllerof. The controllerincludes one or more processors, represented by processor, which are configured to direct the operation of the controllerto control the operation of an automated container cutting system, such as illustrated in. The processormay be a conventional processor such as a microprocessor or a PLC. Additionally, the controllerincludes one or more interfaces, represented by interface, and one or more memories, represented by memory, coupled thereto. The components of the controllercan 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 controllercan include additional components typically included with a controller such as a power supply or power port.

The interfaceincludes multiple ports for transmitting and receiving data to and from components of the automated container cutting system. For example, data representing box dimensions can be received from dimensioning devices. The interfacecan support wireless or wired communications. Additionally, the interfacecan 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 memoryis constructed to store data and computer programs. The memorycan be a conventional memory or data storage. The memorymay be a non-transitory computer readable medium configured to store operating instructions, such as the programming instructions, to direct the operation of the processorwhen initiated thereby. The operating instructions may correspond to one or more algorithms that provide the functionality of the operating schemes disclosed herein. The memory, therefore, stores the programming instructions that direct the operation of an automated container cutting system, such as disclosed herein. The memorycan also store data on different containers, including dimensions, thickness of sides, material, and shape. The processorcan 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 processorcan also generate commands to work with other components of a decanting system. The commands can correspond to one or more steps of method.

In contrast to compliant cutting tool,illustrate different views of an example of a compliant cutting toolwherein the blade depth is not variable and a quick blade exchange is not available.illustrates a front view andillustrates a perspective view. Compliant cutting toolincludes coupler, a sliding mechanism, a wear plate, a blade slot, and a holderthat is visible in.

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

The sliding mechanismis configured to allow movement of the compliant cutting toolalong the axis of the direction of compliance while being moved along the cutting path by the moveable support. The compliant cutting toolcan slide back and forth along the direction of compliance axis while moving along a contoured cut line, such as contoured cut line.

The wear plateis configured to position a blade (not shown) of the compliant cutting toolagainst an outer side surface of a container during cutting. The blade extends through the blade slotand the holdermaintains at least a portion of the wear plateagainst the outer side surface of a container during the cutting. As illustrated in, the holdercan be a spring that pushes at least a portion of the wear plateagainst 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 toolvia the sliding mechanism.

The compliant cutting toolincludes 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 toollocated behind, under, above, or within the wear plate.provides an example of another compliant cutting tool that does not include storage for multiple blades but does allow variable blade depth and angle.

illustrates an example of a compliant cutting toolwherein a blade depth is variable. Features similar to those identified inare identified inusing the same element numbers. In, bladeis also shown.

Varying the depth of bladecan be via a mechanical interface. For example, rotation of a gearof the mechanical interfacecan be controlled via a drive shaftto vary the blade depth by rotating gearof the mechanical interface. At least one pin, protrusion, or another feature can be located on gear, or on a lever or disc connected to gear, to engage one or more slots of bladewhile the gearmoves along a circular path. The bladecan be retained, such as via one or more stationary pins, such that the circular movement of the gearprovides linear movement of the bladeout of the blade slot. 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.