DEVICE FOR INSERTING A BLOCK INTO A PARTLY ASSEMBLED PALLET

Abstract

 The present disclosure relates to a device (1) for inserting a block (102) into a partly assembled pallet (100). The device comprising one or more support surfaces configured to support the pallet and position the pallet within a working area (200), and a first block carousel (10a) which is rotatable about a first axis (A1) orthogonal to the support plane. The first block carousel comprises a first block holding portion (20a) being configured to move from a block loading position to a block delivering position by a rotation of the first block carousel about the first axis. The first block holding portion is positioned at a first distance (L1) from the first axis such that the first block holding portion is movable along an arcuate path. The present disclosure further relates to a method for inserting a block into a partly assembled pallet.

Description

Technical field

[0001] The present disclosure relates to a device for inserting a block into a partly assembled pallet. The present disclosure also relates to a method for inserting a block into a partly assembled pallet.

Background

[0002] Pallets have become a universal standard for packaging and transporting goods. The compatibility of pallets across different industries and countries makes them indispensable for international trade. This globalization of commerce has driven up the demand for pallets significantly. As a result, the pallet repair and recycling industry has also grown to meet the need from businesses seeking cost-effective and sustainable solutions.

[0003] Repairing pallets is an eco-friendly practice that contributes to resource conservation, waste reduction, and a lower carbon footprint. It aligns with the broader global efforts to address environmental challenges and promote sustainable business practices. Businesses that prioritize environmental sustainability are increasingly recognizing the benefits of pallet repair as a means to reduce their environmental impact.

[0004] Modern pallet repair facilities often employ automated equipment, such as pallet nailing machines and robotic systems, to streamline the repair process and improve efficiency. These technologies help reduce labour costs and increase the speed of pallet repair, making it a cost-effective and sustainable solution for businesses within the global supply chain.

[0005] Some prior art systems repair string boards of the pallet by forcing the bottom boards and the top boards of the pallet apart and then pushing the stringer board into its position. However, these systems are not efficient enough and improved method for repairing pallets and different components of the pallets are needed.

Summary

[0006] It is an object of the invention to provide a solution that addresses at least some of the design criteria described above, namely, to provide more efficient devices for repairing pallets and for repairing different components of the pallet. Preferably, the device is more efficient than existing systems for repairing pallets, further reduces the labour costs and increases the speed of pallet repair. Thereby, further improving the sustainable solution of repairing pallets. This has in accordance with a first aspect been accomplished by a device for inserting a block into a partly assembled pallet. The device comprises;

one or more support surfaces configured to support the pallet, to orient the pallet such that a main plane of the pallet extends in parallel to a support plane, and to position the pallet within a working area, and

a first block carousel which is rotatable about a first axis orthogonal to the support plane,

wherein the first block carousel comprises a first block holding portion being configured to move from a block loading position to a block delivering position by a rotation of the first block carousel about the first axis,

wherein the first block holding portion is positioned at a first distance from the first axis such that the first block holding portion is movable along an arcuate path,

wherein, in the block loading position, the first block holding portion is positioned outside the working area,

wherein, in the block delivering position, the first block holding portion is positioned inside the working area.

[0007] The provided device facilitates inserting blocks into a pallet when a block already has been removed from the pallet in an earlier step. This process of inserting blocks into the pallet allows the laborers to leave the repairing line and instead they are allowed to monitor robots which perform the task, whereby the risk of accidents leading to injuries is reduced.

[0008] By the first carousel being mounted at the first axis, it allows for a rotating movement of the first carousel. As the first block holding portion is located at a distance from the first axis, the first block holding portion will move in arcuate path allowing the first block holding portion to move between the block loading position and the block delivering position. The block loading position allow a user or a robot to load the first block holding portion with a block. By rotating the first block holding portion, equipped with the block, from the block loading position to the block delivering position a block may be delivered at a desired position in the pallet. As the pallet is oriented in the working area, the insertion of the block may be performed with high precision. The block may be partly delivered into its desired position by the rotating movement of the first block holding portion and thereafter the pallet may be moved to fully deliver the block. However, in an alternative embodiment, the pallet is first moved into its desired position and thereafter the block is delivered by the first carousel.

[0009] The support surfaces configured to support the pallet provides the position in which the pallet is located in the device allowing the pallet to be worked on by the device. At least some of the support surfaces are configured to abut a perimeter of the pallet. Thereby it is possible to provide a well-defined position of the perimeter of the pallet, and in turn a well-defined positioning of the blocks relative to the perimeter. The first axis is orthogonal to the support plane and allows the arcuate path to be in the support plane, thereby providing the precise movement of inserting the block into the pallet. Further, the arcuate path of the first block holding portion in combination with the fact that pallets typically is formed of orthogonally shaped and oriented pieces, allows the first block holding portion to be inserted in a wedging movement relative to typically orthogonal surfaces of the pallet, rather than distinctly hitting such surfaces, which in turn typically facilitates insertion of a middle block at the position between two corner blocks of the pallet.

[0010] The two positions, the block loading position and the block delivering position, of the first block holding portion are at different stages along the arcuate path of the first block holding portion. The block loading position is a position where the first block holding portion is rotated away from the working area such that the pallet is allowed to be positioned in the working area without having to avoid the first block holding portion. When the pallet is positioned in the working area, the first block carousel may rotate the first block holding portion into the block delivering position and thereby delivering the block into the pallet.

[0011] The working area is described as an area in which the pallet is positioned when insertion of the block is performed. However, as is understood by the skilled person, the working area rather is a working volume as the pallet is in three dimensions. The wording working area is more commonly used and is therefore used throughout the application.

[0012] The device may be positioned as a workstation along a line of different workstations where different operations is performed on the pallet. There may, for example, be earlier workstations where other parts of the pallet are repaired or removed to prepare the pallet for reparation. At the workstation of the device or at a downstream workstation there may be an attachment device, such as a robot, configured to fasten the block to the pallet. This fastening of the block to the pallet may e.g., be performed by a nailing operation. Preferably, the attachment device or robot may fasten the block to the pallet while the pallet is within the working area of said device for inserting a block into a partly assembled pallet. Alternatively, the block may be delivered in the position and then the pallet is moved to a downstream workstation where it is fastened. The attachment device may be a separate device or may be a part of the device for inserting a block into a partly assembled pallet. The pallets may alternatively or complementarily be prepared for reparation by laborers which removes the blocks by hand.

[0013] The first block carousel may further comprise a second block holding portion configured to move from a block loading position to a block delivering position by a rotation of the first block carousel about the first axis.

[0014] The second block holding portion may be positioned at a second distance from the first axis such that the second block holding portion is movable along an arcuate path.

[0015] The first and the second distances of the first and the second block holding portion, respectively, may extend in opposite direction from the first axis.

[0016] The provision of a second block holding portion allows the first block carousel to insert two blocks before it needs to be loaded with new blocks. Some pallets may need reparation of more than one block. In such case the pallet may first be positioned in the working area to allow one block to be inserted and fastened and thereafter change the position of the pallet to insert a second block. Further, the empty block holding portion may be loaded while the other block holding portion is delivering the block and thereby no stops are required to refill blocks. This increases the efficiency of the device.

[0017] The first and second distances extends in opposite directions from the axis such that the first and the second block holding portions is located at opposite sides of the first axis. Thereby, the second holding portion will be located outside of the working area when the first holding portion is located inside the working area. It may be noted that the first and second distances preferably are the same in absolute terms, such that both holding portions are intended to deliver a respective block to corresponding position. However, the distances may alternatively be different such that the two holding portions are intended to deliver a respective block to slightly different positions. This latter may be useful if there are two slightly different kinds of pallets being intended to be repaired.

[0018] A leading side of the first block holding portion, and of the second block holding portion if present, may comprises a wedge portion. The wedge portion may have a height increasing with a distance from the leading side and may thereby be configured to facilitate insertion of the block between two boards of the pallet.

[0019] The two boards may for different reasons be bent or damaged such that the space for the block is less than the intended height. To address this, the wedge portion may have a lower height closer to the leading side and the height may increase until the wedge portion has the same or close to the same height as the block, i.e., slightly smaller, or larger. Thereby, when the first block holding portion is rotated, the leading side with a height lower than the block will first engage the two boards. When the leading side of the block holding portion is further rotated into the boards, the boards are separated such that the block is allowed to be positioned between the two boards. In other words, when the first block holding portion is rotated towards the pallet to insert the block the wedge portion may separate the two boards to allow the block to enter in between the two boards. Further, the wedge portion further enhance a smooth operation of the device as the risk of the first block holding portion hitting the boards, thereby damaging the pallet, during rotation is reduced.

[0020] The wedge portion of the first blocking holding portion, and of the second block holding portion if present, may be shaped such there is formed a slope on both an upper side and a lower side of the wedge portion as seen relative to a plane defined by the arcuate path.

[0021] With the slope on both the upper and lower side of the wedge portion both of the boards may be separated smoothly and allow the block to enter. With the slope on both an upper side and a lower side of the wedge portion both of the boards may be gradually pushed apart.

[0022] A trailing side of the first block holding portion, and of the second block holding portion if present, may be open or openable allowing the first block carousel to be loaded with a block being inserted into the respective block holding portion by a movement of the block towards the trailing side of the respective block holding portion.

[0023] The trailing side being open, or openable, allows for easy insertion of the block into the respective block holding portion. When the block is delivered and preferably also fastened to the pallet, the movement of the first block carousel is limited as the first block holding portion is located inside the working area and inside the pallet and the block is fastened to the boards of the pallet which restricts the movement of the first block carousel. However, the open or openable trailing side allows the first block carousel to be rotated away from the block when the block has been inserted and fastened into the pallet. Further, the open or openable trailing side also allows the pallet to be removed from the working area even when the first block holding portion is inside the working area. By moving the pallet in the direction of the trailing side, the fastened block may be allowed to leave the first block holding portion and thereafter the movement of the pallet may not be restricted by the first block holding portion anymore.

[0024] The first block carousel may be provided with a first support surface facing in a direction along which the leading side of the first holding portion faces and a second support surface facing in a direction along which the leading side of the second holding portion faces.

[0025] The first support surface may be arranged on a first height relative to the support plane, and wherein the second support surface may be arranged on a second height relative to the support plane, the second height preferably being different from the first height.

[0026] By arranging support surfaces on the block carousel, the support surfaces may be used to support the pallet when positioned in the working area. One of the support surfaces may be used when positioning the pallet in the work area and thereafter the first block holding portion is rotated into the pallet. In some cases, the first block carousel need not necessarily be used for inserting a block into the pallet but may rather be used merely as a support for the pallet while other reparation steps are performed on the pallet.

[0027] The different height of the first support surface and the second support surface may be advantageous as the first block carousel may provide support to pallet having different dimensions, such as different heights and/or different thicknesses of the boards. This may also be useful if one of the boards may be missing and in such case the support surface needs to be located at a different height compared to if the board of the pallet is there. Thereby, the first block carousel may ensure that the pallet is in the correct height for inserting the block even if a board of the pallet is missing.

[0028] It is also conceivable to have two supporting surfaces even if there is only the first block holding portion. Then the second support surface may be located at the opposite side of the first block carousel to the first support surface. The first and second support surface may be located at opposite sides of the first axis.

[0029] The device may further comprise a second block carousel which is rotatable about a second axis orthogonal to the support plane,

wherein the second block carousel comprises a first block holding portion being configured to move from a block loading position to a block delivering position by a rotation of the second block carousel about the second axis,

wherein the first block holding portion is positioned at a first distance from the second axis such that the first block holding portion is movable along an arcuate path,

wherein, in the block loading position, the first block holding portion is positioned outside the working area,

wherein, in the block delivering position, the first block holding portion is positioned inside the working area.

[0030] The working area may be rectangularly shaped, and the first block carousel may be positioned along a first side of the working area and the second block carousel may be positioned along a second side of the working area, wherein preferably the first and the second side of the working area may form a corner of the working area.

[0031] The second block carousel may be moveable towards and away from the second side of the working area.

[0032] A second block carousel is advantageous as it allows for inserting two blocks simultaneously. If for example both a corner block and the middle block have been removed, both of these may be provided and repaired at the same time by the first block carousel and the second block carousel. This further enhances the efficiency of the device.

[0033] The working area may be rectangularly shaped as the pallet, or the working area may be a larger area than the one of a pallet such that the pallet may be moved while still being inside the working area. By positioning the first block carousel along the first side of the working area and positioning the second block carousel along the second side of the working area, the device may operate at two sides of the pallet simultaneously. Thereby, block may be inserted into the pallet from all sides just by orienting the pallet in two different positions, which e.g., may be utilized to improve the flexibility of the device.

[0034] Allowing the second block carousel to be moveable towards and away from the second side of the working area may be utilized to facilitate the positioning and removal of the pallet in the working area. The second block carousel may for example be in a position away from the second side of the working area when the pallet is positioned inside the working area. When the pallet has been positioned inside the working area, the second block carousel may be moved towards the second side of the working area and lock the pallet into its position. Then when the reparations have been performed in the device, the second block carousel may be moved away from the second side again, releasing the pallet and allowing the pallet to be removed from the working area. Thus, the movable second block carousel may be used both to position and hold the pallet and to deliver a block.

[0035] The device may further comprise a third block carousel which is rotatable about a third axis orthogonal to the support plane,

wherein the third block carousel comprises a first block holding portion being configured to move from a block loading position to a block delivering position by a rotation of the third block carousel about the third axis,

wherein the first block holding portion is positioned at a first distance from the third axis such that the first block holding portion is movable along an arcuate path,

wherein, in the block loading position, the first block holding portion is positioned outside the working area,

wherein, in the block delivering position, the first block holding portion is positioned inside the working area.

[0036] The working area may be rectangularly shaped, and the first block carousel may be positioned along a first side of the working area and the third block carousel may be positioned along a third side of the working area, wherein preferably the first and the third side of the working area may form a corner of the working area.

[0037] By providing a third block carousel along a third side of the working area, the device may operate simultaneously at three of the sides of the working area. The first block carousel operating at a first side, the second block carousel operating at a second side, and the third block carousel operating at a third side of the working area. This may increase the efficiency of the device even further. As is understood by the skilled person, the first side and the second side may form a first corner of the working area while the first side and the third side may form a second corner of the working area. The respective corner is formed where the respective sides meet up. It may in this context be noted that the sides of the working area are typically not any physical sides but rather merely geometrical sides.

[0038] The device may further comprise a fourth block carousel which is rotatable about a fourth axis orthogonal to the support plane,

wherein the fourth block carousel comprises a first block holding portion being configured to move from a block loading position to a block delivering position by a rotation of the fourth block carousel about the fourth axis,

wherein the first block holding portion is positioned at a first distance from the fourth axis such that the first block holding portion is movable along an arcuate path,

wherein, in the block loading position, the first block holding portion is positioned outside the working area,

wherein, in the block delivering position, the first block holding portion is positioned inside the working area.

[0039] The fourth block carousel may be positioned along the third side of the working area and at a position being different from a position of the third block carousel along the third side.

[0040] With the provision of a fourth block carousel, all the outer blocks of the pallet may be reached in just two different positions of the pallet in the working area. The second and the third block carousel may handle the corner blocks, the first block carousel may handle the block in between the corner blocks and the fourth block carousel may handle a block above the corner block. Further, each block carousel may be designed to act as a support surface to the pallet when the respective block carousel is not operated to insert a block. However, the device may alternatively be designed such that not all block carousels are provided with support surface or surfaces. There may e.g., be three block carousels being provided with support surface or surfaces and a fourth block carousel is not.

[0041] The first block carousel and the third block carousel, and if present the fourth block carousel, may each have a respective fixed position relative to the working area.

[0042] With fixed positions there are fewer moving parts which may be subject to damage and need of maintenance. Thereby, a more robust device may be achieved. Further, the fixed positions reduce the possible sources for errors when positioning the pallet in the working area. With fixed positions it may appear fewer situations where the block carousels are out of position. If an error occurs, it may be a high chance that the error has occurred while positioning the pallet in the working area.

[0043] There are small differences in the size of pallets between different regions such as for example USA and Europe. Hence, in some embodiments the first block carousel, the third block carousel and the fourth block carousel may be moveable between different fixed positions such that the device may be easily adapted to different regional standards. Thereby, the flexibility of the device may be improved, and the device may handle different size pallets.

[0044] The first holding portion of the respective block carousel may further comprise a first pivotably suspended support arranged to form or form part of a first side of the first holding portion, and if the second holding portion is present the second holding portion may comprise a second pivotably suspended support arranged to form or form part of a first side of the second holding portion,
wherein the respective pivotable support may be biased towards a second side being opposite the first side of the respective holding portion.

[0045] The respective pivotable support is biased such that the pivotable support may be pushed away from the respective block holding portion, increasing the size of the opening to insert the block into the respective block holding portion. When the block is inserted, the pivotable support is biased back toward the block and therefore holds the block in its position. The first and second pivotably suspended support may facilitate the insertion of the block into the respective block holding portion while also facilitating the stability of which the block is held in the respective block holding portion.

[0046] Each pivotably suspended support may form or form part of a first side of the respective block holding portion. Thereby, the respective block holding portion may have an open side and one side with the pivotably suspended support.

[0047] The pivotably suspended support may comprise a sensor configured to detect if a block is present in respective block holding portion. The sensor provides information concerning if a block needs to be inserted into the respective holding or if the block holding portion is already loaded with a block. When operating with all the four block carousels, it may be advantageous to know which of the block holding portions of each block carousels that have been used and delivered the block.

[0048] The pivotable suspended support may be a pivotable suspended wheel. The pivotable suspended wheel may facilitate the loading of the block and also the removal of the block when the block is fastened to the pallet. The pivotable suspended wheel is preferably positioned such that wheel facilitate movement of the block towards the open side.

[0049] According to a second aspect of the present disclosure there is provided a method for inserting a block into a partly assembled pallet. The method comprises;

loading a block in a first block holding position of a first block carousel which is rotatable about a first axis orthogonal to the support plane, wherein the first block holding portion is positioned at a first distance from the first axis such that the first block holding portion is movable along an arcuate path,

positioning a pallet on a support surface forming a working area,

inserting the block by rotating the first holding portion from a block loading position to a block delivering position by a rotation of the first block carousel about the first axis, wherein, in the block loading position, the first block holding portion is positioned outside the working area, wherein, in the block delivering position, the first block holding portion is positioned inside the working area, and

attaching the block to surrounding portions of the pallet,

removing the pallet from the working area.

In respect of at least one of the block carousels, the pallet may initially be positioned in an offset position such that a first side and a third side of the pallet has an offset relative to a first side and a third side of the working area, whereafter the block is partly inserted into the pallet, and

whereafter the pallet is positioned in an attaching position having no offset, thereby fully inserting the block into the pallet.

[0050] The advantages of the various features have been discussed above with reference to the device according to the first aspect and those advantages are equally applicable with reference to the above method according to the second aspect. Also, the various variants and preferred embodiments discussed with reference to the device are equally applicable to the above method according to the second aspect.

[0051] The present disclosure may also in short be referred to as relating to a device for inserting a block into a partly assembled pallet. The device comprises one or more support surfaces configured to support the pallet and position the pallet within a working area, and a first block carousel which is rotatable about a first axis orthogonal to the support plane. The first block carousel comprises a first block holding portion being configured to move from a block loading position to a block delivering position by a rotation of the first block carousel about the first axis. The first block holding portion is positioned at a first distance from the first axis such that the first block holding portion is movable along an arcuate path.

[0052] It may be noted that the use of first, second, third, fourth, fifth, etc. are mainly to be seen as labels facilitating reading and that it does not necessarily mean that there need to be all the intervening numbers of block carousels or portions present. However, to facilitate reading, we have consistently used the numbering first, second, third, fourth, etc., as labels, and in a sense based on an embodiment including all conceivable block carousels and portions.

[0053] Further scope of applicability of the present disclosure will become apparent from the detailed description given below. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the disclosure, are given by way of illustration and that various changes and modifications within the scope of the disclosure will become apparent to those skilled in the art from this detailed description.

Brief description of the drawings

[0054] The invention will by way of example be described in more detail with reference to the appended schematic drawings, which shows a presently preferred embodiment of the invention.

Fig. 1

discloses a device for inserting a block into a partly assembled pallet.

Fig. 2

discloses an example of a block carousel.

Fig. 3A-B

disclose two views of a second example of a block carousel.

Fig. 4A-G

disclose a sequence for inserting a block into a partly assembled pallet.

Fig. 5

discloses a method for inserting a block into a partly assembled pallet.

Detailed description

[0055] Fig. 1 illustrates a device 1 for inserting a block 102 into a partly assembled pallet 100. The device 1 may be located along a production line where a defect block already has been removed from the pallet 100. A robot 300 comprising a robot arm 310 with holding means 320 for holding a pallet 100 is located nearby the device 1. The holding means 320 may e.g., be two counter-acting plates, two counter-acting sets of fingers, or the like. Other kinds of holding means 320 are also conceivable, such as the use of one or mor suction cups. The robot 300 may be positioned along the production line and may grab pallets 100 that needs to be repaired and lift these pallets 100 from the production line to the device 1. Further, a block loading arrangement 400 is provided which comprises a plurality of blocks 102 to be loaded into the device 1.

[0056] The robot 300 may position the pallet 100 within a working area 200 of the device 1. The device 1 comprises one or more support surfaces 40a-d, 50a-d configured to support the pallet 100, to orient the pallet 100 such that a main plane of the pallet 100 extends in parallel to a support plane, and to position the pallet 100 within the working area 200. The support surfaces that are configured to support the pallet 100 also provides the position in which the pallet 200 is located in the device 1 thereby allowing the pallet 100 to be worked on by the device 1. The support plane may basically be said to be a plane defined by the support surfaces and the bottom surface or alternatively the top surface of the pallet 100 rests on the support surfaces such that said bottom surface or alternatively the top surface of the pallet 100 coincides with the support plane.

[0057] The device 1 further comprises in accordance with the preferred embodiment shown in the drawings, a first block carousel 10a which is rotatable about a first axis A1 orthogonal to the support plane, a second block carousel 10b which is rotatable about a second axis A2 orthogonal to the support plane, a third block carousel 10c which is rotatable about a third axis A3 orthogonal to the support plane and a fourth block carousel 10d which is rotatable about a fourth axis A4 orthogonal to the support plane. Each axis A1-A4 allow each block carousel 10a-d to rotate. The block carousels 10a-10d will be further described in connection to Fig. 2 and Fig. 3A-3B. It may in this context be noted that the inventive concept does not necessarily involve the presence of all the above-mentioned block carousels 10a-d. The provision of a first block carousel 10a provides a basic design addressing the problem set forth, and the addition of one or more of the second to fourth carousels 10b-d provides more advantageous designs.

[0058] The working area 200 is typically, essentially rectangularly shaped, and the first block carousel 10a is positioned along a first side 210 of the working area 200. The second block carousel 10b is positioned along a second side 220 of the working area 200. The second block carousel 10b is moveable towards and away from the second side 220 of the working area 200. The first 210 and the second 220 side of the working area 200 forms a corner of the working area 200. The third block carousel 10c is positioned along a third side 230 of the working area 200. The first 210 and the third 230 side of the working area 200 forms a corner of the working area 200. As is understood by the skilled person, the first side 210 and the second side 220 forms a first corner of the working area 200 while the first side 210 and the third side 230 forms a second corner of the working area 200. The corners are formed where the sides meet up. It may in this context be noted that the sides of the working area 200 refers to geometrical lines. The fourth block carousel 10d is positioned along the third side 230 of the working area 200 and at a position being different from a position of the third block carousel 10c along the third side 230. The first block carousel 10a, the third block carousel 10c, and the fourth block carousel 10d, each have a respective fixed position relative to the working area 200.

[0059] There are differences in the size of pallets between different regions such as for example USA and Europe. Hence, in some embodiments the first block carousel 10a, the third block carousel 10c and the fourth block carousel 10d may be moveable between different fixed positions such that the device may be easily adapted to different regions standards. Thereby, the flexibility of the device 1 may be improved, and the device 1 may handle different size pallets.

[0060] With four block carousels 10a-d all the outer blocks 102 of the pallet 100 may be reached by just positioning the pallet 100 in two different positions in the working area 200. The second 10b and the third 10c block carousel may provide the two corner blocks along the first side 210, the first block carousel 10a may provide a block in between the two corner blocks along the first side 210, and the fourth block carousel 10d may provide a block along the third side 230 being adjacent the corner block at the corner between the first and third sides 210, 230. Further, each block carousel 10a-d may act as a supporting surface to the pallet 100 when the block carousel is not operated to insert a block 102.

[0061] In Fig. 2 a detailed view of the first block carousel 10a is illustrated. The first block carousel 10a comprises a first block holding portion 20a being configured to move from a block loading position to a block delivering position by a rotation of the first block carousel 10a about the first axis A1. The first block carousel 10a further comprises a second block holding portion 30a configured to move from a block loading position to a block delivering position by a rotation of the first block carousel 10a about the first axis A1. The first block holding portion 20a is positioned at a first distance L1 from the first axis A1 and the second block holding portion 30a is positioned at a second distance L2 from the first axis A1. The first L1 and the second L2 distances of the first 20a and the second 30a block holding portion, respectively, extends in opposite direction from the first axis A1. In other words, the first L1 and second L2 distances extends in opposite directions from the first axis A1 such that the first 20a and the second 30a block holding portions is located at opposite sides of the first axis A1. Thereby, the second holding portion 30a will be located outside of the working area 200 when the first holding portion 20a is located inside the working area 200. As the first block holding portion 20a and the second block holding portion 30a are each located at a respective distance from the first axis A1, the first block holding portion 20a and the second block holding portion 30a will each move in a respective arcuate path allowing the first block holding portion 20a and the second block holding portion 30a, respectively, to move between the block loading position and the block delivering position. If one of the block holding portions 20a, 30a is positioned in the block loading position, the other block holding portion 20a, 30a is positioned outside the working area 200. If one of the block holding portions 20a, 30a is positioned in the block delivering position, the other block holding portion 20a, 30a is positioned inside the working area 200.The two positions, the block loading position and the block delivering position, of the first block holding portion 20a and the second block holding portion 30a are at different stages along the arcuate path of the first block holding portion 20a and the second block holding portion 30a. The block loading position is a position where the first block holding portion 20a or the second block holding portion 30a is rotated away from the working area 200 such that the pallet 100 is allowed to be positioned in the working area 200 without having to avoid the first block holding portion 20a. When the pallet is positioned in the working area 200, the first block carousel 10a may rotate the first block holding portion 20a or the second block holding portion 30a into the block delivering position and thereby delivering the block 102 into the pallet 100. It may in this context be mentioned that the block delivering positions of the two block holding portions 20a, 30a is one and the same position as seen relative to the working area 200, namely a position inside the working area 200. Correspondingly, the block loading positions of the two block holding portions 20a, 30a is one and the same position as seen relative to the working area 200, namely a position outside the working area 200. How the first block holding portion 20a is rotated into the block delivering position is indicated in Fig. 4B.

[0062] The first block holding portion 20a and the second block holding portion 30a each comprises a leading side 22a, 32a which each has a wedge portion 23a, 33a. Each wedge portion 23a, 33a is in accordance with the preferred embodiment shaped such that there is formed a slope on both an upper side 24a, 34a and a lower side 25a, 35a of the wedge portion 23a, 33a as seen relative to a plane defined by the arcuate path. The wedge portion 23a, 33a has a height which increases with an increased distance from the leading side 22a, 32a and is configured to facilitate insertion of the block 102 between surrounding portions, i.e., two boards of the pallet 100. In other words, the wedge portion 23a, 33a has a lower height closer to the leading side 22a, 32a and the height may increase until the wedge portion 23a, 33a has the same, slightly larger, or at least close to the same height as the block 102. Thereby, when, for example, the first block holding portion 20a is rotated, the leading side 22a with a height lower than the block 102 will first engage the two boards and when the leading side 22a of the block holding portion 20a is further rotated into the boards, the boards are separated such that positioning of the block 102 between the two boards is facilitated.

[0063] The first block holding portion 20a and the second block holding portion 30a each comprises a trailing side 26a, 36a. The trailing side 26a, 36a is open or openable allowing the first block carousel 10a to be loaded with a block 102 by a block 102 being inserted into the respective block holding portion 20a, 30a by a movement of the block 102 towards the leading side 22a, 32a of the respective block holding portion 20a, 30a.

[0064] When the block 102 is fastened to the pallet 100, the movement of the first block carousel 10a is limited due to that the first block holding portion 20a is located inside the working area 200 and inside the pallet 100 and due to that the block 102 is fastened to the boards of the pallet 100 which restricts the movement of the first block carousel 10a. However, the open trailing side 26a allows the first block carousel 10a to be rotated further and away from the block 102 when the block 102 has been inserted and fastened into the pallet. Likewise, the open trailing side 26a also allows the pallet 100 to be removed from the working area 200 even when the first block holding portion 20a is inside the working area 200a. By moving the pallet 100 in the direction of the trailing side 26a, the fastened block 102 may be allowed to leave the first block holding portion 20a and thereafter the movement of the pallet 100 may not be restricted by the first block holding portion 20a anymore. This will be further described in connection to Fig. 4A-G.

[0065] The first block carousel 10a is provided with a first support surface 40a facing in a direction along which the leading side 22a of the first holding portion 20a faces and a second support surface 50a facing in a direction along which the leading side 32a of the second holding portion 30a faces. The first support surface 40a is arranged on a first height h1 relative to the support plane, and the second support surface 50a is arranged on a second height h2 relative to the support plane. The second height h2 may be the same as, or may be different from the first height h1. This is best illustrated in Fig. 3b.

[0066] The first block holding portion 20a of the first carousel 10a further comprises a first pivotably suspended support 60a, which in the preferred embodiment is a pivotably suspended wheel, that form part of a first side70a of the first block holding portion 20a. The second holding portion 30a comprises a second pivotably suspended support 62a, which in the preferred embodiment also is a pivotably suspended wheel, that form part of a first side 72a of the second holding portion 30a. The respective pivotably suspended support 60a, 62a is biased towards a second side 74a, 76a of the respective block holding portion 20a, 30a that is opposite of the first side 70a, 72a of the respective block holding portion 20a, 30a. The respective pivotably suspended supports 60a, 62a is biased such that the pivotably suspended support 60a, 62a may be pushed away from the respective block holding portion 20a, 30a, thereby increasing the size of the opening allowing a block 102 to be inserted into the respective block holding portion 20a, 30a. When the block 102 is inserted, the pivotably suspended support 60a, 62a is biased back toward the block 102 and therefore holds the block 102 in its position. For the first block carousel 10a, the first side 70a, 72a and the second side 74a, 76a of each block holding portion 20a, 30a are different from the trailing side 26a, 26a and from the leading side 22a, 32a of the respective block holding portion 20a, 30a. Thereby, each of the block holding portions 20a, 30a each has along a first direction a first side with the pivotably suspended support 60a, 62a and an opposing second side 74a, 76a, and along a second direction the leading side 22a, 32a and the opposing open trailing side. With a pivotably suspended wheel, the loading of the block 102 and also the removal of the block 102 when the block 102 is fastened to the pallet 100 may be facilitated. The pivotable suspended wheel is positioned such that wheel facilitate movement of the block towards the open trailing side 26a, 36a. Each pivotably suspended support may further comprise a sensor 42 configured to detect if a block 102 is present in respective block holding portion 20a, 30a.

[0067] Turning to Fig. 3A and 3B, an example of disclosure of a second block carousel 10b, a third block carousel 10c and a fourth block carousel 10d is provided. Each block carousel 10b-d is rotated around the respective axis A2-A4 such that a first block holding portion 20b-d, located at a first distance L1 to the respective axis A2-A4, and a second block holding portion 30b-d, located a second distance L2 to the respective axis A2-A4, are rotated along an arcuate path, as described above, moving each block holding portion 20b-d, 30b-d between a block loading position and a block delivering position. Further, each block holding portion 20b-d, 30b-d is provided with a leading edge 22b-d, 32b-d and with a first support surface 40b-d and a second support surface 50b-d as described in connection to Fig. 2. As seen in Fig. 3B the first support surface 40b-d has a first height h1 and the second support surface 50b-d has a second height h2, which in the preferred embodiment are different from each other.

[0068] However, the design of the second, third and fourth block carousels 10b-d in Fig 3A-3B differs from the first block carousel 10a shown in Fig. 2 especially with regard to the design of the trailing side. The trailing side 26a, 36a of the first block carousel 10a is open, while each trailing side 26b-d of the block holding portions 20b-d, 30b-d of the second, third and fourth block carousel 10b-d comprises the pivotably suspended support 60b-d, 62b-d. In other words, for the second, third and fourth block carousel 10c-d, the trailing side 26b-d, 36b-d is the same as a first side of each holding portion 20b-d, 30b-d, while the trailing side 26a, 36a of the first block carousel 10a is different from the first side 70a, 72a of the respective block holding portion 20a, 30a. Further, each block holding portion 20b-d, 30b-d of the respective block carousel 10b-d is provided with an open side 28b-d, 38b-d being opposite of the respective axis A2-A4. The open side 28b-d, 38b-d and the trailing side 26b-d, 36b-d with the pivotably suspended support 60b-d, 62b-d allows the block 102 to be inserted to the respective block holding portion 20b-d, 30b-d.

[0069] It should be noted that for each block carousel 1 0b-d, it is the rotation direction which decide which sides that are leading or trailing. Hence, the block carousel may be mirrored compared to the example in Fig. 3A and 3B. Further, there may be different variation of which block carousel that is according to the example in Fig. 2 and which block carousel that is according to the embodiment of Fig. 3A-3B. For example, in Fig 1, the first block carousel 10a is arranged as described in Fig. 2. The second block carousel 10b and the fourth block carousel 10d rotates in a first direction around its respective axis A2, A4 and the third block carousel 10c rotates in the opposite direction around its axis A3. Thus, in the third block carousel 10c the trailing side 26c and the leading side 22c is opposite compared to the second block carousel 10b and the fourth block carousel 10d.

[0070] Turning to Fig. 4A to 4G, a sequence of figures describes how the device 1 may operate. In other words, a method 500 for inserting a block 102 into a partly assembled pallet 100 is provided. As illustrated in Figs. 2 and 3A, a respective block 102 is loaded into each block holding portion 20a-d, 30a-d while the block holding portions 20a-d, 30a-d are located in the respective block loading position. When the block holding portions 20a-d, 30a-d have been loaded with blocks 102, a pallet 100 that needs a new block 102 will be grabbed by the holding means 320 of the robot arm 310 and positioned inside the working area 200. This is illustrated in Fig. 4A. The pallet 100 may initially, as illustrated in Fig. 4B, be positioned in an offset position such that a first side 110 and a third side 130 of the pallet has an offset L3 relative to a first side 210 and a third side 230 of the working area 200. However, it may also be positioned directly without an offset; i.e., in a position as illustrated in Fig. 4D. In Fig. 4B it is also illustrated how the first block holding portion 20a of the first block carousel 10a starts rotating from the block loading position towards the block delivering position. As can be seen, the leading side 22a with the wedge portion 23a has entered between the boards of the pallet 100 and started to prepare room for inserting the block 102. In Fig. 4C the movement of the first block holding portion 20a from the block loading position to the block delivering position is completed. Hence, the block 102 in the first block holding portion 20a is partly inserted into the pallet 100 positioned in the offset position.

[0071] In Fig. 4D it is illustrated how the pallet 100 is moved by the robot arm 310 to a position in the working area 200 without offset. In other words, the first side 110 of the pallet 100 is positioned at the first side 210 of the working area 200 and the third side 130 of the pallet 100 is positioned at the third side 230 of the working area 200. The first block holding portion 20a of the first block carousel 10a is still in the block delivering position and thereby the block 102 is fully inserted to its position inside the pallet 100.

[0072] When the block 102 is fully inserted in its position inside the pallet 100, the second carousel 10b is moved towards the second side 220 of the working area 200. Thereby, the pallet 100 is forced towards and locked into its intended final position in the working area 200. This is illustrated in Fig. 4E. Locking the pallet 100 into its intended final position facilitates the fastening of the block 102 to the surrounding portions of the pallet 100. The fastening may for example be performed by a nailing robot that nails the block 102 to the boards of the pallet 100.

[0073] In Fig. 4F, the block 102 has been attached to the surrounding portions of the pallet 100, and the second block carousel 10b is moved away from the second side 220 of the working area 200. Thereby, the pallet 100 is released and thereby the pallet 100 is allowed to be moved towards the second side 220 of the working area 200. When the second block carousel 10b has been moved, the pallet 100 is allowed to leave the working area 200 by first moving the pallet 100 towards the second side 220 of the working area and thereafter to leave the working area 200 fully. Thereby, the pallet 100 may be removed from the working area 200. The first block carousel 10a requires the robot arm 310 to first move the pallet 100 towards the second side 220 of the working area 200 due to the pivotably suspended support 60a that blocks a direct movement out from the working area 200. Alternatively, the pivot function of the pivotably suspended support 60a may be designed such that it may be completely removed out of the path of the block 102 such that the pallet 100 may be removed in a single translational movement in a direction away from the first side 210. However, since the second block carousel 10b preferably is moveable along the direction of the first side 210 to accomplish a holding effect, this movability may be utilized also when removing the pallet 100 from the working area 200.

[0074] In Fig. 5, a method 500 for inserting a block 102 into a partly assembled pallet 100 is illustrated. The method comprises loading 510 a block 102 in the first block holding portion 20a of the first block carousel 10a which is rotatable about the first axis A1 orthogonal to the support plane. The first block holding portion 20a is positioned at the first distance L1 from the first axis A1 such that the first block holding portion 20a is movable along an arcuate path.

[0075] The method 500 further comprises positioning 520 the pallet on a support surface forming a working area 200.

[0076] The method 500 further comprises inserting 530 the block 102 by rotating the first holding portion 20a from a block loading position to a block delivering position by a rotation of the first block carousel 10a about the first axis A1. The method 500 may alternatively or complementary include inserting other blocks 102 with the use of any of the second to fourth block carousels 10b-d.

[0077] The method 500 further comprises attaching 540 the block 102 to surrounding portions of the pallet 100. The method 500 may alternatively or complementary include attaching other blocks 10, which has/have been placed with the use of any of the second to fourth block carousels 10b-d, to surrounding portions of the pallet 100.

[0078] The method further comprises removing 550 the pallet 100 from the working area 200.

[0079] Further details of the method 500 have been discussed above with reference to the functionality and design of the different block carousels 10a-d.

[0080] Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage.

Claims

1. A device (1) for inserting a block (102) into a partly assembled pallet (100), the device (1) comprising;

one or more support surfaces configured to support the pallet (100), to orient the pallet (100) such that a main plane of the pallet (100) extends in parallel to a support plane, and to position the pallet (100) within a working area (200), and

a first block carousel (10a) which is rotatable about a first axis (A1) orthogonal to the support plane,

wherein the first block carousel (10a) comprises a first block holding portion (20a) being configured to move from a block loading position to a block delivering position by a rotation of the first block carousel (10a) about the first axis (A1),

wherein the first block holding portion (20a) is positioned at a first distance (L1) from the first axis (A1) such that the first block holding portion (20a) is movable along an arcuate path,

wherein, in the block loading position, the first block holding portion (20a) is positioned outside the working area (200),

wherein, in the block delivering position, the first block holding portion (20a) is positioned inside the working area (200).

2. The device (1) according to claim 1, wherein the first block carousel (10a) further comprises a second block holding portion (30a) configured to move from a block loading position to a block delivering position by a rotation of the first block carousel (10a) about the first axis (A1),

wherein the second block holding portion (20a) is positioned at a second distance (L2) from the first axis (A1) such that the second block holding portion (30a) is movable along an arcuate path,

wherein the first (L1) and the second (L2) distances of the first (10a) and the second (30a) block holding portion, respectively, extends in opposite direction from the first axis (A1).

3. The device (1) according to claim 1 or 2, wherein a leading side (22a, 32a) of the first block holding portion (20a), and of the second block holding portion (30a) if present, comprises a wedge portion (23a ,33a), the wedge portion (23a, 33a) having a height increasing with a distance from the leading side (22a, 32a) and being configured to facilitate insertion of the block (102) between two boards (104, 105) of the pallet (100).

4. The device (1) according to claim 3, wherein the wedge portion (23a, 33a) of the first blocking holding portion (20a), and of the second block holding portion (30a) if present, is shaped such there is formed a slope on both an upper side (24a, 34a) and a lower side (25a, 35a) of the wedge portion (23a, 33a) as seen relative to a plane defined by the arcuate path.

5. The device (1) according to any one of the preceding claims, wherein a trailing side (26a, 36a) of the first block holding portion (20a), and of the second block holding portion (30a) if present, is open or openable allowing the first block carousel (10a) to be loaded with a block (102) being inserted into the respective block holding portion (20a, 30a) by a movement of the block (102) towards the trailing side (26a, 36a) of the respective block holding portion (20a, 30a).

6. The device (1) according to any one of claims 3-5 when dependent upon claim 2, wherein the first block carousel (10a) is provided with a first support surface (40a) facing in a direction along which the leading side (22a) of the first holding portion (20a) faces and a second support surface (50a) facing in a direction along which the leading side (32a) of the second holding portion (30a) faces,
wherein the first support surface (22a) is arranged on a first height (h1) relative to the support plane, and wherein the second support surface (32a) is arranged on a second height (h2) relative to the support plane, the second height (h2) preferably being different from the first height (h1).

7. The device (1) according to any one of the preceding claims, further comprising a second block carousel (10b) which is rotatable about a second axis (A2) orthogonal to the support plane,

wherein the second block carousel (10b) comprises a first block holding portion (20b) being configured to move from a block loading position to a block delivering position by a rotation of the second block carousel (10b) about the second axis (A2),

wherein the first block holding portion (20b) is positioned at a first distance (L1) from the second axis (A2) such that the first block holding portion (20b) is movable along an arcuate path,

wherein, in the block loading position, the first block holding portion (20b) is positioned outside the working area (200),

wherein, in the block delivering position, the first block holding portion (20b) is positioned inside the working area (200),

wherein the working area (200) is rectangularly shaped, and the first block carousel (10a) is positioned along a first side (210) of the working area (200) and the second block carousel (10b) is positioned along a second side (220) of the working area (200), wherein preferably the first (210) and the second (220) side of the working area (200) form a corner of the working area (200), and

wherein the second block carousel (10b) is moveable towards and away from the second side (220) of the working area (200).

8. The device (1) according to any one of the preceding claims, further comprising a third block carousel (10c) which is rotatable about a third axis (A3) orthogonal to the support plane,

wherein the third block carousel (10c) comprises a first block holding portion (20c) being configured to move from a block loading position to a block delivering position by a rotation of the third block carousel (10c) about the third axis (A3),

wherein the first block holding portion (20c) is positioned at a first distance (L1) from the third axis (A3) such that the first block holding portion (20c) is movable along an arcuate path,

wherein, in the block loading position, the first block holding portion (20c) is positioned outside the working area (200),

wherein, in the block delivering position, the first block holding portion (20c) is positioned inside the working area (200),

wherein the working area (200) is rectangularly shaped, and the first block carousel (10a) is positioned along a first side (210) of the working area (200) and the third block carousel (10c) is positioned along a third side (230) of the working area (200), wherein preferably the first (210) and the third (230) side of the working area (200) form a corner of the working area (200).

9. The device (1) according to claim 8, further comprising a fourth block carousel (10d) which is rotatable about a fourth axis (A4) orthogonal to the support plane,

wherein the fourth block carousel (10d) comprises a first block holding portion (20d) being configured to move from a block loading position to a block delivering position by a rotation of the fourth block carousel (10d) about the fourth axis (A4),

wherein the first block holding portion (20d) is positioned at a first distance (L1) from the fourth axis (A4) such that the first block holding portion (20d) is movable along an arcuate path,

wherein, in the block loading position, the first block holding portion (20d) is positioned outside the working area (200),

wherein, in the block delivering position, the first block holding portion (20d) is positioned inside the working area (200),

wherein the fourth block carousel (10d) is positioned along the third side (230) of the working area (200) and at a position being different from a position of the third block carousel (10c) along the third side (230).

10. The device (1) according to claim 8 or 9, wherein the first block carousel (10a) and the third block carousel (10c), and if present the fourth block carousel (10d), each have a respective fixed position relative to the working area.

11. The device (1) according to any one of the preceding claims, wherein the first block holding portion (20a-d) of the respective block carousel (10a-d) further comprises a first pivotably suspended support (60a-d) arranged to form or form part of a first side (70a-d) of the first block holding portion (20a-d), and if the second block holding portion (30a-d) is present the second block holding portion (30a-d) comprises a second pivotably suspended support (62a-d) arranged to form or form part of a first side (72a-d) of the second holding portion (30a-d),
wherein the respective pivotable suspended support (60a-d, 62a-d) is biased towards a second side (74a-d, 76a-d) being opposite the first side (70a-d, 72a-d) of the respective block holding portion (20a-d, 30a-d).

12. The device according to claim 11, wherein the pivotably suspended support (60a-d, 62a-d) comprises a sensor (42) configured to detect if a block (102) is present in respective block holding portion.

13. The device according to claim 11 or 12, wherein the pivotable suspended support is a pivotably suspended wheel.

14. Method (500) for inserting a block into a partly assembled pallet, the method comprising

loading (510) a block in a first block holding portion of a first block carousel which is rotatable about a first axis orthogonal to the support plane, wherein the first block holding portion is positioned at a first distance from the first axis such that the first block holding portion is movable along an arcuate path,

positioning (520) a pallet on a support surface forming a working area,

inserting (530) the block by rotating the first holding portion from a block loading position to a block delivering position by a rotation of the first block carousel about the first axis, wherein, in the block loading position, the first block holding portion is positioned outside the working area, and wherein, in the block delivering position, the first block holding portion is positioned inside the working area, and

attaching (540) the block to surrounding portions of the pallet,

removing (550) the pallet from the working area.

15. The method according to claim 14, wherein in respect of at least one of the block carousels, the pallet is initially positioned in an offset position such that a first side and a third side of the pallet has an offset relative to a first side and a third side of the working area, whereafter the block is partly inserted into the pallet, and
whereafter the pallet is positioned in an attaching position having no offset, thereby fully inserting the block into the pallet.

Drawing