AU2008255183A1 - Improvements in palletising systems - Google Patents

Description

Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT (ORIGINAL) Name of Applicant: Visy R & D Pty Ltd Actual Inventor: Craig Bryant Address for Service: DAVIES COLLISON CAVE, Patent Attorneys, 1 Nicholson, Melbourne, Victoria 3000. Invention Title: "Improvements in palletising systems" Details of Associated Provisional Application: No: 2007906702 The following statement is a full description of this invention, including the best method of performing it known to us: Q:\OPER\TNB\2008\December\3066944 9 Decemberdoc - 9/12/08 P-OPER\TNB\SPEC\306%44 Impovmes in Paetising Sysms Spci.doc-9/12/2008 IMPROVEMENTS IN PALLETISING SYSTEMS Field This invention relates to improvements in palletising systems, and particularly systems 5 capable of concurrently palletising multiple SKU (stock control units) each of relatively low volume at a reasonable capital cost. Background The packaging and shipping of produce, such as kiwi fruit, present particular difficulties due to the low volumes requiring grading, separation and packaging in 10 palletised loads for transport. In a typical operation, twenty or more infeed lines deliver cartons or trays of graded and packaged produce, which must then be palletised into loads having connon characteristics. In the past, much of the palletising operation has been conducted with relatively high labour content, leading to high packaging and handling costs. 15 Summary It is an object of the present invention to provide a palletising system capable of efficiently handling multiple infeed lines to produce palletised loads of packaged goods. It is a further object to provide improved mechanisms for use in palletising systems which enable the more efficient handling of packaged goods. 20 In a first aspect, the invention provides a palletising system comprising a multiplicity of infeed lines, one or more layer-forming shuttles operable to form layers of packaged goods received from multiple infeed lines in predetermined patterns, means for squaring and compacting each formed layer, and palletising means for transferring each compacted layer to one of a multiplicity of pallets. 25 The layers of packaged goods may be in the form of stacks or columns of trays or other stackable containers. In the case of kiwi fruit, each stack will contain approximately 20 kilograms of produce. In one form a layer-forming shuttle/table may be adapted to service about six infeed lines, and for this purpose, is adapted to travel on tracks extending transversely of 30 the array of infeed lines. The palletising system may include a pickup table arranged at the end of each POPER\TNBSPECl\3069%84 Improvmms i Paleising Systems Speidoc-9/12/2008 -2 squaring means, and including means for elevating each compacted layer to allow fork access for transfer by the palletising means. The palletising means may take any suitable form, including a gripping head incorporating lifting forks and squaring devices mounted on a robotic arm for gripping a 5 compacted layer from the compacting and squaring means, or suitable low level palletisers arranged to receive compacted layers from the compacting and squaring means for transfer to a selected one of a multiplicity of pallets. Where low level palletisers are used, no pickup table is required. In another aspect, the invention provides a method of palletising packaged goods 10 comprising the steps of receiving packaged goods from a multiplicity of conveyor infeed lines, aligning a layer-forming table with one of said infeed lines to receive packaged goods for the formation of a layer according to a predetermined pallet pattern, moving the loosely assembled layer to a squaring table for squaring and compaction, moving the squared and compacted layer to a predetermined one of a multiplicity of pallets, and then 15 repeating the process for each of the multiplicity of infeed lines until a predetermined number of pallets have been completed. The layer-forming table is movable transversely of the multiplicity of infeed lines to allow alignment with each of the infeed lines as dictated by a suitable control system. Depending on the number of infeed lines, more than one layer-forming table may be 20 provided, and may be arranged on suitable tracks so as to be capable of movement to each of a selected number of the infeed lines. Where the squared and compacted layer is to be transferred using a gripper or similar palletising device, the squared and compacted layer is delivered to a pickup table having means for elevating the layer to enable the penetration of forks or the like under the 25 layer for transfer of the layer to a pallet. The palletising step may include a squaring step to ensure that the packaged goods are properly aligned to allow the assembly of stacks or columns on the pallet with locating tabs ensuring proper location of each package with respect to the others. In a further aspect, the invention provides a control system for a palletising system 30 having a multiplicity of packaged product infeed lines and a multiplicity of pallet load stations, said control system including line allocation means for allocating packaged product from a particular infeed line to a particular pallet load station.

P)PER\TNB\SPEC\306% 4 mirov u in Pallcising Syms Spi doc-9/12/200S -3 The control system may include product line control means, such as a touch-panel, which indicates the required product stack height for the next palletising operation as well as the number of stacks required. The line allocation means may be operated by a "mouse dragging" operation from a 5 selected line indicator to the required pallet load station. If desired, the system may include a profile change process which allows a line allocation to be changed while the system is running. The above aspect will be better understood and further detail concerning the control system will be found in Annexure A forming part of this specification. 10 In another aspect, the invention provides a mechanism or orienting packaged goods to allow the formation of layers suitable for palletising, comprising driven rollers for supporting and transferring a package, package orienting means nested between the rollers and mounted for elevation and rotation to achieve package orientation, the driven rollers being mounted for lateral movement to position the package for transfer to a predetermined 15 position, and package supporting transfer means operable to transfer each package to a predetermined position against a barrier means for accumulation of a layer of packages suitable for palletising. In one form, the driven rollers, the package orienting means and the transfer means are supported on a carriage which is adapted to travel on tracks or the like so as to receive 20 packaged goods from a multiplicity of conveyor infeed lines. The package orienting means may comprise a plurality of support elements spaced to nest between adjacent rollers and supported by a central column including means for elevating and rotating the column to change the orientation of a package supported by the elements. The nesting of the elements between the rollers is such that when the elements 25 are lowered between the rollers to their nested position, the rollers engage the package to transfer it to the transfer means for the assembly of a layer of packaged goods. In one form the transfer means is a driven belt. In another aspect, the invention provides a gripper for mounting on a robotic arm or the like, comprising a support structure adapted for attachment to a robotic arm and 30 carrying opposed fork assemblies adapted for movement towards and away from each other to support or release a layer of packaged goods, opposed load squaring plates also mounted on the support structure for movement towards and way from each other to P:VPER\TNB\SPEC\3066944 Impro nts in Palctising Sysms Spci doc-9/12/2OOS -4 square and align the layer to be transferred by the gripper. In one form, the gripper includes a pair of additional squaring plates positioned inwardly of the opposed fork assemblies and intermeshed with the forks to allow for squaring of a load before it is palletised. 5 Embodiments of each of the above aspects will be described in greater detail below. It will be understood that while the following description refers to the palletising of produce such as kiwi fruit, the various aspects of the invention are equally applicable to the palletising of any packaged goods, the system being particularly useful for use with packaged goods of low volume multiple stock control units. 10 Description of Drawings Figure 1 is a schematic diagram of one embodiment of a palletising system; Figure IA is a block diagram illustrating the control system applicable to the palletiser of Figure 1; Figure 1B is a schematic illustration of the position of the various control panels of the 15 operating system; Figures IC to 1FF illustrate various operator screens associated with the control panels used to control the system; Figure 2 is a schematic diagram of typical pallet patterns suitable for use in the palletising system; 20 Figure 3 illustrates stacks of packaged kiwi fruit arranged in a predetermined pallet pattern; Figures 4 to 9 illustrate a layer-forming shuttle/table including a novel package orienting mechanism; Figures 10 and II illustrate a package layer squaring mechanism and pickup table; Figures 12 to 21 illustrate a gripper head for a robotic arm suitable for palletising layers of 25 packaged goods from the pickup table; Figures Al to A5 illustrate the positions of control input detectors used to control the operation of the system; and Figure 22 illustrates an alternative palletising system. Description of Embodiments 30 Currently all grading, packing and post-packing of kiwi fruit is highly labour intensive, because it requires concurrent palletising of multiple SKU's of low volume. The PM PERTNB\SPECl\3069844 Improvm ts in Palleising SyVs Spcci doc-9/12200 - 5 palletising system described below aims to minimise the labour component associated with palletising in order to reduce associated costs and the inherent occupational health and safety issues associated with the heavy repetitive lifting involved. The system eliminates the requirement for manual palletising, corner post insertion, and pallet strapping, and 5 since a grader typically sorts fruit to approximately thirty drops, or packing tables, it is proposed that twenty of the grader lines will be automated by the system to be described. Since each grader employs approximately twelve people for palletising activities, and five people for strapping and moving pallets into storage, and since most production occurs within a fifty hour working week over a packing season typically lasting around ten weeks 10 per year, the automated palletising system developed by the Applicant will offer significant labour saving possibilities. Referring firstly to Figure 1 of the drawings, an automated palletising system I embodying the invention will be seen to include a multiplicity of infeed conveyors 2 (say twenty), package layer-forming table/shuttles 3, each of which accepts packages from one 15 of several of the infeed conveyors 2 by travelling on tracks or the like to selected infeed conveyors under the control of a central control system such as illustrated in Figure IA. Each layer-forming table/shuttle 3 is associated with a fixed squaring table and tie sheet station 4 each of which has an associated pickup table 5 including a layer elevating mechanism which allows each layer of packaged goods to be lifted by a gripper 20 mechanism 6 mounted on each of two robot arms 7 which transfer layers of packaged goods to selected pallets (P) located on load station conveyors 8 which deliver completed pallets to a pallet outfeed conveyor 9. Empty pallets are delivered to the conveyors 8 by a pallet shuttle 10 from a pallet dispenser 11. This system palletises and straps boxes of kiwi fruit. The grader and some manual 25 handling present the system with 20 infeed lines 2. These infeed lines feed onto three layer forming shuttles that run on a single track. The layer formers 3 form a complete pallet layer from one infeed conveyor and transport it to one of three tie sheet conveyors 4. The pallet layer gets compressed and squared on the tie sheet conveyors 4 to remove gaps and allow an operator to place a tie sheet if required. Once the product has left the tie sheet 30 station it is presented to one of two robots 7 for picking. Once picked, the two robots, on tracks T, will move to one of the fifteen pallet load stations L, where they will place the pallet layer. A pallet shuttle 10 will collect the completed pallet P and move it to the P.0PER\TNB\SPECl306%944 Imprmes in Palletising Sysmms Spcidoc.9/12/2003 -6 outfeed conveyors while another pallet shuttle will be bringing an empty pallet for replacement. Once on the outfeed conveyors, the completed pallet will have straps applied by the strapper S and will present itself for collection by forklift. There will be a pallet dispenser to dispense empty pallets into the system as well as infeed conveyors to re 5 introduce semi-completed pallets. The system has been divided up into areas that can run and stop independently of each other, including: box infeed, layer formers, tie sheet conveyors, load stations, pallet outfeed. To manage the system, a main operator interface control M is located at a 10 mezzanine level Figure 1A, and system configuration and operation controls include set-up and profile change, allocation of lines, alarms and system diagnostics and manual controls. As described above, the infeed area consists of twenty infeed conveyors 2 in the form of line shaft roller conveyors, where operators prepare stacks of kiwi fruit trays which are displayed on the control panel associated with each individual line. Operators fill the 15 system by pushing the stacks from gravity conveyors to the line shaft roller conveyors, and when the required configuration is achieved, the control panel displays a "GO" button. If the configuration is incorrect, the operator has the ability to reverse the roller conveyor via a touch screen PI to P20 associated with each conveyer 2. The system checks for the correct number of stacks by means of sensors (not shown) and lifts an entry gate to prevent 20 new boxes coming in until all stacks are delivered to the next operation step. The layer forming shuttle/table 3 is requested by the control system to pick up the accumulated stacks and travels to the prepared infeed conveyor. The exit gate and associated roller brake on the infeed conveyor retracts and releases one stack at a time to the layer-forming shuttle 3. 25 As each stack is transferred onto the layer-forming shuttle 3, a sensor checks the stack height, and a wrong stack height prompts the operator to correct the stack, the operation being stopped until the stack is rectified. The stacks are positioned on the layer forming shuttle 3 according to the predetermined pallet pattern, as will be described in further detail below. The currently active recipe determines which of the infeed lines the 30 layer-forming shuttles service. After collating the layer, the shuttle 3 travels to one of three pre-assigned layer squaring tables 4, and transfers the complete layer stack onto the table 4. The squaring PA)PER\TNB\SPEC30696&44 Improvmnu in Palleising Sysm Spcido-9/12/2003 -7 table 4 ensures that the layer is correctly aligned and that there are no gaps between the packages or cartons. The operator has access via a light guard for visual inspection and for placing a tie sheet if required. The system continues after the operator pushes the Go button and the completed layer travels to the associated pickup table 5 where it bears 5 against a stop. The layer is then raised and a pickup request is sent to the robot 7. The appropriate robot 7 travels along its base axis to the pickup table 5, and the gripper head 6 is operated to position its forks under the layer for transport to one of fifteen pallet loading stations 8 predetermined by the selected recipe to build a complete pallet. The gripper head 6 has a clamp arrangement to support the load while it is transported and 10 for ensuring load alignment during placement on the pallet. When the pallet has been completed, the full pallet is discharged from the loading station via a full pallet shuttle. After receiving the pallet, the shuttle travels to the outfeed conveyor and transfers the pallet onto the outfeed conveyor. The full pallet shuttle is used to discharge partially built pallets out of the system during set-up and profile changes. 15 The empty pallet shuttle delivers new empty pallets to the load stations. The empty pallet shuttle is replenished by the pallet dispenser and associated conveyors. During set-up and profile change the empty pallet shuttle introduces any required partially complete pallets back onto the pallet loading stations. The outfeed conveyor system transfers the full pallets to the strapping machine. 20 The strapping machine places corner boards and straps the pallet automatically according to the strapping configuration and sequence set by the selected recipe. Once the pallet strapping is finished the pallet is transferred to the exit conveyor for removal by forklift. The cross transfer area has an entrance for manual packed pallets so that they can be strapped. 25 In case of profile or set-up change when strapping is not required the pallet travels though the strapper to the exit conveyor and omits the strapping operation. Before proceeding to describe the various components of the palletising system, it is appropriate to provide an overview of the operator panels provided by the system, with reference to Figures 1A to 1K of the drawings. The operator interface of the system 30 consists of: * Main control panel M: Set-up and profile changes are managed at this station, as well as line allocation, alarms and diagnostics of the system.

PWPER\TNhrSPEC1\3069644 Improeet 'm P.fa sing Syste s doc.9/12/208 -8 " Product lines touch-panels P1 to P20: These panels show instructions on how to prepare the next layer. They also provide manual controls, allowing the operators to rectify any issues with the product stacks. * Pallet infeed/outfeed information screen Puo: This screen gives information about the 5 last ejected pallet, and also requests for reintroduced pallets upon a set-up change. The position of the above screens is illustrated schematically in Figure 1B. Each product line touch-panel P1 to P20 has a screen that indicates the required stack height for the next pick from the input conveyors 2, as well as the number of stacks required. This is illustrated in Figure 1 C. Using this screen, the operator prepares the stacks 10 as specified on the screen. A label on the side of the conveyor indicates the correct position for the last stack. Safety There are thirteen emergency stop buttons located around the system as well as an emergency stop button at each infeed touch-panel. Any emergency stop will immediately 15 stop the entire system. To enter the system there are gates at intervals around the fence. These gates will be locked by a solenoid and this solenoid is controlled by the PLC. The gates will only be unlocked when the system has come to a complete stop. These gates, when unlocked and opened, will only affect the local area in which they are placed. The rest of the system will 20 continue to run. There are a number of light guards around the system, some of these have a muting facility and some of them do not. The muting enables product to pass through the light guard without tripping the safety circuit. If a pallet gets stuck in a light curtain that hasn't muted correctly there is an override switch to allow the conveyor motors to run even 25 though the light guard is broken. The light guards at the tie sheet stations do not have muting and will stop the conveyors as soon as they are broken. The two light guards in the load station area are inactive until a gate leading into the area is open. These light guards are there to allow one robot to continue palletising while the other is stopped and people in the guarded area. None of the shuttles or conveyors are able to run during this time and if 30 the light guard is breached then both robots will shut down immediately. Resetting after safety breaches P:OPER\TNB\SPEC\306%844 Improvm in Pacising Sysmms Spei~do-9/12/200 -9 If an emergency stop is pressed the SAFETY button on the system setup page, shown above, will be red. Pressing this button will open the safety screen which will display an over view of the system with the status of each emergency stop, safety gate and light curtain. The offending emergency stop will be flashing red. 5 To reset the emergency stop, ensure the offending emergency stop button has been released, turn button clockwise, then press the emergency stop reset button, located on the main panel M. To reset a guard fault, such as a light guard or safety gate, ensure the gate is closed or light guard reset and press the start button. This will automatically lock the gate, reset 10 the safety relay and start the system. If some emergency stops or light guards are shown to be broken but, in fact, aren't. The safety logic controller has probably gone into fault. To reset this press the Safety ErrAck button located in the left banner. Light guard override 15 In the event that a pallet gets stuck in the light guard, there is an override function. To enable the light guard override turn the key switch located at the light guard control box. While holding the key switch in the override position the area must be reset and start pressed. The key switch will need to be held in the override position until the light guard is clear of obstruction. 20 Tower lights The system tower lights are: Green solid: All areas running. Green flashing: Running with one or more areas stopped. Amber flashing: Fault. 25 Red solid: Emergency stop pressed. Red flashing: Emergency stop relay not reset. Siren: Sounds for 3s before any area starts. As well as the main tower light on the MCC, there are green tower lights at each area. These will be solid green when the area is running and flashing green when the area 30 is starting. They will be off if the area is stopped or in fault. System status screen P PER\TNBSPEC1\36%9 44 Improvnnu in Pa.ctisin8 Sysitms Spcidoc.9/12/2005 - 10 As shown above, the system status screen shows an overview of the entire system broken down into areas and then elements within each area. Each area will be animated a different colour depending on the current area status. These colours will be: Green - Running 5 Red - Fault Grey - Stopped Blue - Manual As well as the area showing red when in fault, there will be a red icon to indicate where the fault has occurred. The alarm banner, bottom of screen, will give a more detailed 10 description of the fault. Once the fault has been reset the alarm will disappear from the alarm banner. From the system status screen each area can be stopped and placed in manual independently of other areas. To place an area in manual: 15 1. Stop area 2. Press manual button 3. Press start button for that area to lock gates and reset safety To get an area out of manual press the manual button again. The current configuration screen (Figure 1C) shows the system's current 20 configuration. It shows which infeed line is feeding which layer former. Where the layer formers are unloading and which robot is placing the product on which load station. By holding the cursor over a pallet or infeed conveyor, the path of that product will be highlighted. From this screen there is the ability to eject pallets from the load stations. The 25 pallet will eject from the system, when eject pallet button pressed, once the product currently in the system for that pallet has been palletised. There will also be an immediate eject pallet button which will disregard any remaining product in the system for that pallet. This button will need a password for access as any product left in the system for that pallet will need to be removed manually (this feature should only be used to recover the system 30 from an abnormal situation). The system setup screen (Figure ID) is where the line allocation and the product type for each line is selected.

P'OPER\TNB\SPEC\3069644 Improvemts in Palliting Sysms Spcidoc-9/2/2003 - 11 Once each setup is complete it can be given a 4 letter ID (A) and saved for future reference. To save the configuration press the SAVE button (I) and enter a filename to save to. Eastpack may develop a naming convention including the date and production type. To load a configuration press the LOAD button (J) and select the file to load. 5 The steps to set up a configuration are as follows: 1. Click on the drop to configure (D) 2. Drag the line to the desired pallet (E) 3. Select the box style (B) 4. Select the drop product size (C) 10 5. Select the pallet type (F) 6. Select the pallet product size (G) 7. Select if a new or re-introduced pallet is required (H) Once all required drops and pallets have been allocated press the VALIDATE button (M) to check for any errors. If there are errors, e.g. different product size from drop 15 to pallet, then an error message will appear showing where the problem is. If setup is valid then the PREPARE button (N) will enable. The PREPARE button sends information to the pallet infeed HMI so the forklift drivers can begin preparing the pallets that need to be re introduced. Once the prepare button is pressed the APPLY button (M) will be enabled. Pressing the apply button will start the system setup. All products currently in the system 20 will be palletised and all pallets with product ejected. Any infeed conveyor that does not have a complete pallet layer present will reverse and the product will need to be manually loaded on the product change conveyor. Once all pallets are ready to receive product the system will restart. The CAPTURE button (K) captures and displays the current configuration. 25 The SET LIMITS button (Figure 1 E) (L) is a password-protected button that allows the user to select the travel limits for the layer former. This advanced feature should only be used in the event of malfunction of a layer former or robot. On the profile change screen (Figure IF) the operator is able to change part of the 30 current configuration. To change the current configuration follow the steps as described in system setup for each drop that needs to be re-allocated. The operator can select to wait for the end of the pallet before ejecting or eject straight away (A). The CAPTURE PAPER\TNB\SPECI\30696S44 Impovemts in Palctising Sysins Spcidoc-9/12/200 - 12 CONFIGURATION button (B) displays the current configuration. Once configuration has been changed press the VALIDATE button (C) to check for errors and then the APPLY button (D) to apply changes. The product tracking screen (Figure 1G) shows data for each position throughout 5 the process. It shows the number of layers on infeed conveyors, tie sheet conveyors, robot grippers and pallets. The layer formers screen (Figure 1H) shows information about the drives associated with the layer former as well as providing the operator the ability of reset. While a layer is being formed, the RESET button (A) will reset the current layer. 10 All boxes that have moved onto the conveyor belt will need to be removed and placed on the infeed conveyor. The layer former will then re-start the layer forming process. The motors section shows some basic information about each motor. Wether the motor is referenced or in fault. These boxes will be green when healthy and red when not. This section will also provide a JOG and a REFERENCE button for the rotator, if it's not 15 referenced. The communications screen (Figure 1I)shows the communication layout for the system. If there is a communications fault then the offending node will be highlighted red. Robots screen. The robot screen (Figure IJ) shows the current status of the robot as well as 20 commands to home the robot. The status bar will show what the robot is currently doing, e.g. waiting for gripper to open, normal operation, etc. The other status indicators show if the robot is in teach mode, play mode or remote mode. The robot needs to be in remote mode for automatic operation. There is also indication of program running, alarm, communication error and 25 low battery. To start the robot from the beginning of the program and move it to a clear position press the HOME button. There is no fixed home position for the robot, it will merely move straight up from wherever it is to a clear position. The pallet shuttle screen (Figure 1K) will show information about each pallet 30 shuttle. A. The current position window will show the position of the shuttle in millimetres. B. The destination window will give a description of the shuttles destination.

PO0PEkTN8\SPEC\3069644 Imprvm s in Pa!Ieising Symsn Spi.doc-9/2/20OS - 13 C. RESET DESTINATIONS button will reset both pallet shuttle destinations and send them to the park positions at either end of the track. If for some reason both shuttles are trying to drive to the same position or past one another then they will stop on the track and just sit there. To recover from this situation 5 press the DESTINATION RESET button. This will send the shuttles to either end of the track and reset which conveyor they are both trying to pick from. The pallet dispenser (Figure IL) will dispense one pallet at a time when needed. Empty pallets are loaded into the pallet bin and, when required, the tynes will lower the pallets to the conveyor back out of the bottom pallet and lift the remaining pallets clear. 10 The dispensed pallet will travel to the end of the conveyor and wait for a pallet shuttle to collect it. The pallet bin has three sensors attached to it. One for high level, low level and empty. The high level and empty sensors will stop the pallet dispenser from dispensing while the low level sensor will bring a warning up on the HMI. One pallet will be left on 15 the tynes when the pallet dispenser is empty. There are sensors mounted in the floor to disable the pallet dispenser motors when a forklift is present to prevent machine damage. The tower lights are: Green steady: Normal operation. 20 Green flashing: Low pallets. Amber flashing: Pallets empty or fault. The pallet dispenser screen shows the status of sensors as well as allowing manual jogging of the motors. If the pallet dispenser stops, and there is no apparent fault and pallets are present, it 25 may have overrun one of its sensors. To overcome this jog the motors until 2 sensors are on then place the area back into automatic. The maintenance screen (Figure IM) allows the user to view and control each component of the system. By pressing one of the information buttons (A) the user will be able to see a screen such as this. 30 In these manual screens (Figure IN) the user will be able to see the status of each sensor (A). These will be green when the sensor is on.

P:0PER\TNB\SPEC1\306964 Impro,.n in Pllising Sysm Specidoc-9/12/2008 - 14 If the corresponding area is in manual then motors and valves will be able to be manually controlled from these screens. Pushing the motor forward or reverse buttons (B) will drive the motor until the button is released. For valves there will be a button to energise each solenoid. 5 The data for each pallet position can also be seen and changed on these screens. Type the data and then hit enter for each change required. The shuttle calibration screen (Figure 10) is where the layer forming shuttles and the pallet shuttles can be calibrated. Calibration would need to occur if the barcode scanner has been bumped or moved and the shuttle cars are not lining up correctly with the 10 conveyors, or if the barcode tape is replaced. To calibrate the shuttles: 1. Jog shuttle to correct calibration position (A) 2. Press the calibration button (B) The help button (C) will bring up a detailed description of where the shuttle car 15 needs to line up for calibration. Layer former 1, 2 & 3: Centralise each layer former with their respective tie sheet conveyor. Pallet shuttle I & 2: Both pallet shuttles need to be calibrated at load station 1. Line up shuttle conveyor chains with the load station conveyor chains. 20 Once calibrated the calibration positions can be saved to file and reloaded in future if necessary. The shuttle calibration screen will be password protected. The set label positions screen (Figure IP) sets up which side of the box the label will be on. This setup can be saved to file and loaded at a later date. 25 Height sensing disabled If the height sensing disabled has a tick against it, then the height sensing for the layer formers has been turned off. The edit recipe screen (Figure 1Q) allows the user to change parameters of a recipe. These screens will be password protected. 30 To change a recipe: 1. Select recipe or create new name (A) 2. Press the EDIT button (C) PM)PER\TNB\SPEC\306%&44 Improvmnu in Pilletising Systems Spcidoc.9/1212008 - 15 3. Select pack style (E) 4. View pack style to ensure measurements are correct (F). The Pack Style window will appear. To change pack style (Figure IR): 5 1. Select box style or create new one (1) 2. Press edit to change data (2) 3. Ensure recipe has a unique index (4) 4. Enter the box dimensions (5) 5. Enter the weight (6) 10 6. Save recipe (3) 5. Select pallet pattern (G) 6. View pallet pattern to ensure correct pattern and label orientation (H). The Pallet Pattern screen will appear. To change pallet pattern (Figure IS): 15 1. Select pallet pattern or create new pattern (1) 2. Press edit (2) 3. Ensure recipe has unique index (4) 4. For each box on layer (5) select position on pallet (6) and where label should face (7) 20 5. Save changes (3) 7. Check stacking sequence is correct (I). If not press the edit button (J). The Stacking Sequence screen will appear. To change stacking sequence (Figure IT): 1. Select number of layers for pallet (2) 25 2. Click on the pick or tie sheet where you need to insert (1) 3. Insert either pick (3) or tie sheet (4) or delete item (5) NOTE: Stacking sequences should only be modified by qualified personnel or the system manufacturers. 8. Check strap pattern is correct (K), if not press edit (L). The Strap Pattern screen 30 will appear. Select the required strap pattern (Figure IU). By pressing the EDIT button the description can be changed.

PAOPER\TNB\SEC1\30696844 mrovmes in Palleising Sysmms Spci doc-9/12/200S - 16 Advanced The advanced menu allows you to view each individual infeed HMI as well as the pallet outfeed HMIs. GLOBAL RESET resets all the data in the infeed part of the system. 5 After pressing global reset all pallets will need to be ejected and all product will need to be manually cleared from the system The infeed HMI screens (Figure lAA) show the operator how many trays are required by the layer former for the next layer. In this example the operator needs 8 stacks of 4 layers. There is also information about the drop number, pallet destination, how many 10 loads left to complete the pallet and pack style. The star designates that this drop has priority over the other drops for the same pallet and will be picked next. The GO button will remain red and disabled until the correct number of trays is present on the infeed conveyor. Once the correct number of trays is present the button will turn green and, once pressed, will call the layer former to collect the trays. A message will 15 appear on the screen (Figure 1 BB) saying it is waiting for layer former. The MANUAL button (Figure 1CC) can be used by the operator to control the infeed conveyor. They can manually drive the conveyor forward or reverse. This may be useful if there is a stack with the incorrect number of trays. Pressing AUTO will return the screen to the normal window. Note: The area does not need to be in manual for the 20 MANUAL buttons to work. To align the stacks correctly on the infeed conveyors, a guide will be fitted to push the stacks up against. This must be done for correct layer forming. The manual control screen (Figure 1 DD) also allows the operator to start and stop the product change conveyor. 25 If the incorrect height of a stack has been detected by the layer former a fault message will display on the infeed HMI. The rollers on the layer former and the infeed conveyor will be then automatically reversed, until the stack is back on the infeed conveyor. The operator must ensure that the height of all stacks is correct and that no liners are sticking out through the flaps of the boxes, and finally press the FIXED button. 30 Tie sheet conveyors If a tie sheet is required the pallet layer will not move forward after being compressed by the layer squarer. The green mushroom button will flash to indicate a tie P:OPER\TNBSPEC\3069644 Impov ts in Palietising Sysans Specidoc-9/12/2003 - 17 sheet is required. The operator will enter through the light guard and apply the tie sheet. Once completed the operator will reset the light guard and allow the pallet layer to continue by pressing the mushroom button. Pallet outfeed 5 There is an inspection platform after the strapper for the application of top boards. Pallets will stop on this conveyor, if a top cap is required, to allow the operator to place the top cap. Once the top cap is placed the operator will need to press the green mushroom button for the pallet to proceed. At the manual pallet load conveyor there will be an HMI touch screen for the 10 operator to enter strapping details of the pallet (Figure EE). The pallet will not transfer to the strapper until the data is entered and the OK button pressed. To enter the strapper area, first stop the area and then open the gates. Both the strapper and conveyor will be safety stopped and safe to perform normal operational activities on it, e.g. replacing strapping material. 15 There is also area control for the strapper on the outfeed HMI screen. The strapper HMI screen (Figure 1 FF) shows the status of the strapper area and the status of the strapper. The area can be stopped and started from this screen also. The EJECT PALLET button will eject the current pallet in the strapper but not allow another pallet to enter. This will need to be used if the corner boards become empty 20 during a strapping operation. The BYPASS button will bypass the strapper and send the pallets out to the manual-loading conveyor. This will allow people to be working on the strapper and allow the system to continue to run. The pallet infeed/outfeed HMI (Figure IGG) shows the pallet number of the pallet 25 on the last outfeed conveyor as well as the pallet number required to be re-introduced at the infeed. If a half finished pallet is on the last outfeed conveyor then the operator will need to mark the pallet with the correct pallet number so it can be re-introduced at a later time. The infeed half of the screen will show the pallet numbers of all pallets required to 30 be re-introduced and in bold will show the next pallet to load on the conveyor. There will also be a button to allow an empty pallet to replace a half finished pallet, e.g. if a pallet P:OPER\TNB\SPEC\3069644 Improvcm s in Palleising Systems Spei ci .9/12/2OO - 18 number is being displayed in bold and there is no pallet of that number then press the empty pallet button and the shuttle will collect from the pallet dispenser. Referring now to figures 4 to 8 of the drawings, the layer-forming table/shuttle 3 is illustrated in more detail. The supporting carriage 300 is mounted on driven wheels 301 5 (Figure 5) which are driven to move the carriage 300 transversely along tracks or the like into alignment with the infeed line 2 under the control of the main control system. The carriage 300 supports a carton orienting mechanism 302 and a driven belt 303 which receives cartons from the orienting mechanism 302 until they engage a stop 304 at the end of the belt 303. Detectors 305 are positioned at the corners of the belt 303 and 10 provide detection at either end of the belt 303 and diagonally across the belt 303 so that the system can detect that no cartons are on the belt 303. The carton orienting mechanism 302 is mounted for transverse movement across the end of the transfer belt 303 so that the cartons may be positioned across the belts in the required pallet pattern. Figures 6 and 7 show the orienting mechanism 302 at the ends of 15 movement across the transfer belt 303. The carton orienting mechanism 302 includes driven rollers 306 and a carton elevating and rotating support 307 which is configured to nest between the rollers 306 as illustrated in the drawings. The support 307 is mounted on a central column (not shown) which is driven to elevate from the position shown in Figure 4 to the position shown in 20 Figure 5 and to rotate as illustrated in Figure 8. When the support 307 is in its nested position (Figure 4), the bottom of the carton engages the rollers 306 to enable cartons to be positioned on the mechanism 302 and to be transferred from the mechanism 302 to the transfer belt 303. In the elevated position illustrated in Figure 5, the support 307 is able to be rotated to achieve appropriate orientation of the carton for positioning and label reading 25 purposes. Thus by driving the mechanism 302 across the transfer belt 303 and rotating the support 307, cartons can be positioned for transfer onto the transfer belt 303 in the appropriate pallet pattern illustrated in Figure 2, one of which is shown in Figure 3. Referring now to Figures 10 and 11, the squaring table 4 and pickup table 5 are illustrated and shown in layout with regard to the associated gripper robot 7. The squaring 30 table 4 includes a driven belt 400 and opposed squaring beams 401, 402 arranged to move towards and away from each other by means of driven cranks 403. Layers of cartons are transferred from the layer-forming table 3 once the stop bar 304 has been retracted and the POPER\TNB\SPECI\3069644 Impo mu in Pallesing Spei.doc-9/12/20S -19 layer advances to a stop bar (not shown) and the squaring beams 401 402 are moved inwardly to square and compact the layer. The squared and compacted layer is then transferred from the table 4 to the pickup table 5 which comprises driven belts 501 and layer elevating members 502 between the 5 belts 501 and spaced suitably to receive the forks of the gripper/forklift mechanism 6 described further below. Referring now to Figures 12 to 21, the gripper/forklift mechanism 6 is illustrated in greater detail, and will be seen to comprise a central support structure 600 adapted for attachment to a robot arm in a known manner. The support structure 600 supports a pair of 10 opposed fork structures 602 603 and opposed clamping arms 604 605, with additional squaring arms 606 607 positioned within the fork structures 602 603 as illustrated. The fork structures 602 603 are made of carbon fibre. Each fork structure 602 603 includes spaced depending support arms 608 609 which are mounted for inward and outward movement on tracks carried by the support 15 structure 600 and driven pneumatic cylinders 609 610. The lower end of each support arm 607 608 carries a cross member 611 which carries a multiplicity of spaced forks 612 which extend inwardly towards the opposing assembly. The opposed clamps/grippers 604 605 include similar support arms which carry clamping/gripping plates 613 which are capable of movement up and down by cylinders 20 614, while the arms are moveable inwardly and outwardly via drive means 615. The squaring members 606 and 607 are similarly mounted and moveable upwardly and downwardly as illustrated and will be seen to include open squaring plates 616 which intermesh with the forks 612 as illustrated. Figures 16 to 21 illustrate the fork assemblies 602 603, the clamps 604 605 and the 25 squaring members 606 607 in various operating positions. As previously described, the clamping plates 613 operate to support the load while it is transported, while the squaring members 606 607 ensure alignment of the load during placement on the pallet. Referring now to Figures Al to A5 and Figure 1, the infeed conveyors 2 are 30 controlled as follows, with reference to Figure Al: e When running in Auto mode, the conveyor will run forward unless the reverse request is on (in the event of a profile change or incorrect height detected at P:\OPER\TNB\SPECj\3069644 Improvemets in Paeising Sysems Spi doc-9/12/200 - 20 Layer Former). " When the reverse request is on, the entry gate will be lowered and the conveyor will be reversed until all the PEs 1-6 are clear for more than a certain time. e The speed of the conveyor will be 15 m/min unless the exit gate XG is down 5 (when feeding boxes to Layer Former) in which case the conveyor will run at 30 m/min. " The entry gate EG will be up until a new layer is required. The PEs on the conveyor will constantly check if all the stacks are in position (according to the product style, a number of PEs have to be ON and the rest OFF). Once the 10 sensors detected a correct box level on the conveyor, the 'GO' button on the touch-screen PI-P 20 will be enabled. * When the 'GO' button is pressed, the "Layer Ready" output will be set. " The layer forming table/shuttle 3 will travel to this line and set the "Ready to receive product" signal. The conveyor will then drop the exit gate XG and feed 15 a box. The Layer Former 3 will turn off the 'Ready to receive product' signal until the rotating conveyor 306, 307 is back in position and clear of boxes. The process is then repeated until the layer is completed. * If the Layer Ready signal is set, the Layer Former 3 is not in position and all the PEs are OFF, reset the Layer Ready output and request new stacking data. 20 e While the Layer Ready signal is set, the layer preparation details on the HMI are hidden (no new data will be provided until the current layer is delivered). The layer-forming shuttle 3 (LF) is operated as follows, referring to Figure A2: * When Available, the only possible state transition is to Travelling to Product Infeed, as soon as a product infeed contains enough of the next required product 25 to form a layer. " Once the LF is in receiving position, the Layer Former at Line X output is set. Then, it will run the Rotator roller conveyor at 30 m/min and set the "Ready to receive product" bit. The infeed conveyor 2 will then start feeding one stack at a time. 30 * Upon reception of a new stack, the stack height will be checked. The corresponding product height will be obtained according to the style, and then PM)PER\TNB\SPEC\3069644 Improems in Palleising Sysems Spci doc.9/12/2003 -21 multiplied by the "Layers in this delivery" to obtain the correct stack height. If the measured height is incorrect, set a specific fault number and reverse the conveyors. 0 If a correct height is detected, the box will continue to be conveyed until is 5 centred in the rotator roller conveyor (after a trailing edge is detected on PEl, drive rollers for a distance calculated using the stack length, the roller conveyor length and the distance between the PE and the rotator conveyor). Reset the "Ready to receive product" bit to prevent further stacks from coming in until the current one is delivered to its final position. 10 e The next step involves moving the rotator sideways to the target position for the current stack. SideShift = f(style, stacknumber). These positions have to be coded in a way that allows simple addition of new pallet patterns. * As the rotator is travelling sideways, the box will be rotated 90deg (if required). Rotation = f(style, stack_number). Before turning, the rotator needs to be 15 extended using the rotator lift cylinder, as described above. 0 Finally, the rotator conveyor will drive the product to its final position and travel back to the centre of the LF. Once back there, set the "Ready to receive product" bit back on again (except for the last box). * When the last stack is received, store the input data structure into a set of 20 variables * If the layer is finished, travel to the corresponding TS conveyor 4,5 and set the product information on the output data structure. Wait there until the "TS conveyor ready to receive layer" is on; turn on the main conveyor until PEs 2, 3 and 4 are clear for a few seconds. Clear the product information. 25 e If the LF is clear of product and not travelling anywhere, travel to the next requested line. Referring to Figure A3, the pickup table on the sheet status 4 operates as follows: * If the clamping position is clear and the motor is running, turn on the "Ready to receive product" signal. 30 e Set the "Tie sheet required indicator LED" if applicable (lHz flashing indication) P:OPER\TNB\SPEC\3069644 Impove-mts in Palletising Sysems Speidoc-9/12/2009 - 22 " Raise the gate Gc. * Run the conveyor at full speed until a trailing edge is detected on PEI; slow down to f/2 until PE2 goes on, then stop. * Extend the clamps. Wait until the "Done PB" is pressed (the operator will press 5 this button after placing the tie sheet). Retract the clamps and clear the LED indication. * Lower the gate Gc. * Wait until the pick area is clear (with layer lifter down) and transfer the layer. * When PE4 is made, raise the lifter 502 and set the "Layer ready to be picked" 10 signal. " The data needs to be transferred with the pallet as it travels from clamping position to picking position. The palletising robots 7 (Figure 1 and Figures 11 to 21), operate as follows: All the robot gripper cylinders and sensors will be controlled by the PLC. There 15 will be a Beckhoff EtherCat module on the gripper while the robot will communicate via Profibus to the PLC. When a pallet layer has been formed on the pick off conveyor 5 the robot 7 will be told to pick and given the pick off conveyor number. The robot will move above the pick position and request the PLC to retract the squaring flaps 613, extend the tynes 612 and 20 extend the product clamps 616. The PLC will then pass the robot the status of reed switches and when all reed switches are correctly on, the robot will move to the pick position. Once in the pick position the robot will request the tynes to retract and, once retracted, will pick the layer off the conveyor and set the pick complete signal. The PLC will confirm that the pick is complete by setting the pick complete handshake signal; the 25 robot can then reset the pick complete signal. When the robot is picking it will also need to capture the pallet destination and the product weight in kg. The robot will then move to the correct pallet and check the pallet height from the PLC. This will be in millimeters from the bottom of the pallet. The robot will then extend the squaring flaps, wait for the flaps to be extended and move to the top of the pallet stack. 30 The robot will then clamp the product and retract the tynes. Once the tynes are retracted the product clamps can be released and the robot will set the place complete signal, wait for the place complete handshake signal, reset the place complete signal and move from P.0PER\TNB\SPEC\306644 Imporanns in Palltising Systems Spei doc.9/2/2oo -23 the pallet. Referring to Figure A4, the pallet shuttles operate as follows: In normal operating conditions there will be one shuttle 5 for picking full pallets from the pallet conveyors and one shuttle for picking empty or re-introduced pallets. Both 5 shuttles will be able to do both jobs in the event of one of them going off line. When a pallet is finished the conveyor will call the shuttle to come and pick. The conveyor number will get loaded in a first in first out (FIFO) array and transferred to the shuttle when it is ready. The shuttle will be ready for a new conveyor pick number when there is no pallet on the shuttle and the shuttle is not already committed to a pick. When the 10 shuttle is in position for the pick it will set the ready to receive pallet signal. The shuttle and pallet conveyor will run in reverse until both sensors on the shuttle are covered. Once the shuttle has picked the completed pallet it will move to the outfeed conveyor, set the ready to give pallet signal, and wait for the outfeed ready to receive product signal. Once the signal is received the shuttle will run in reverse until both sensors are clear. 15 When a pallet conveyor calls a shuttle to pick, the other shuttle will pick an empty or re-introduced pallet from the infeed. The shuttle will move to the infeed and set the ready to receive pallet signal. It will run the motors forwards until both sensors are covered. Once the pallet is on the shuttle it will move to the destination conveyor and set the ready to give pallet signal. The motors will run forward until both sensors are clear. 20 To prevent collisions a priority bit will pass between the two shuttles. If one shuttle has priority then the other shuttle will not be able to have priority. For example: If one shuttle has to pick from conveyor nine for example, and the other shuttle has to place at conveyor four it is impossible for both shuttles to get to their destination. Therefore whichever shuttle does not have the priority bit on will have to wait fro the other shuttle to 25 complete its job. Both shuttles will know the position of the other shuttle and will not be allowed to come within a certain distance of each other. Referring to Figure A5, the load status conveyors 8, operate as follows: When empty, the load station will call for a new pallet from the pallet shuttle. When the shuttle is in position and has set the ready to give product signal, the conveyor 30 will run forward until the pallet in position sensor is covered. The pallet in position signal will then be set to the robot. If an empty pallet is supplied then the empty pallet signal will be set as well.

P:\PER\TNB\SPEC\306%&44 Improv ts in Pallisng Sysms Spei.do-9I2/200 - 24 When the robot has completed a pallet or a protocol/profile change has occurred the conveyor will set the ready to give pallet signal to call the shuttle. When the shuttle is in position with the ready to receive pallet signal high, the conveyor will run in reverse until the shuttle ready to receive pallet signal is off. 5 Referring to Figure 1, the pallet infeed conveyors operate as follows: Pallets will be fed into the system as either semi-completed pallets or empty pallets. Semi-completed pallets will be loaded one by one onto the conveyors while empty pallets will be loaded as a stack into the pallet dispenser bin. Pallets will travel on the conveyors to their shuttle pick position and set the ready to 10 give pallet signal. Once the shuttle has arrived and set the ready to receive pallet signal the conveyor will run forward until the shuttle ready to receive pallet signal has turned off. To determine whether an empty pallet or a half finished pallet is re-introduced into the system the operator will make a selection on a touch screen. The pallets will need to be loaded on in order and will be assigned a pallet conveyor number. If a half completed 15 pallet is re-introduced then the PLC will measure the height of the pallet before it is fed onto the pallet shuttle. The pallet dispenser will dispense one pallet at a time using two motors and a set of forklift tynes. A stack of pallets will be loaded into the bin where the forklift tynes will lift all but the bottom pallet. This bottom pallet will then transfer along the conveyor to the 20 pallet shuttle. Referring to Figure 1, the pallet outfeed conveyors operate as follows: The outfeed conveyors can receive a pallet from either the pallet shuttle or from a forklift. When receiving from the pallet shuttle, the shuttle will set the ready to give pallet signal. If there is room on the conveyor the ready to receive pallet signal will be set and the 25 cell outfeed conveyor will run until the pallet in position sensor is covered. From the cell outfeed conveyor, or manual infeed conveyor, the pallet will get transferred to the transfer conveyor. The transfer conveyor will then raise and transfer onto the strapper infeed conveyor. The infeed conveyor will then transfer to the strapper conveyor until the pallet gets to the strapper stop gate. If straps are required the strapper 30 will be told the appropriate strap configuration and to start its cycle. Once the strapper cycle complete signal is on the strapper stop gate will lower and the pallet will transfer to the first strapper exit conveyor then onto the second strapper exit conveyor and finally to PA)PER\TNB\SPECI\30696 4 mpm ens in Palletising Sysans Spi do.912/2008 - 25 the third strapper exit conveyor. The alternative embodiment illustrated in Figure 22 is similar to the previously described embodiment with the exception that the robot arms are replaced by two mobile low level plate palletisers 4 of known construction. In operation: 5 * Bundles are accumulated wide face leading at the end of each drop on conveyors 1. For an eight down pallet pattern for example, operators will manually form eight short stacks of product, each stack nominally twenty kilograms of product. (Depending on tray format, the time required to accumulate the required quantity of trays will be approximately ten to fifteen 10 minutes). * When the required number of trays have been accumulated at the end of a given drop, one of three layer formation devices 2 will automatically index to the drop and feed the product from the drop onto the table, orientating each column of trays as required. 15 0 Formed layers are subsequently delivered to one of four pre-squaring and buffer stations 3, from where interlocking can also be applied if required. * One of the two mobile low level plate palletisers 4 then retrieve the preformed product and palletise it to the appropriate pallet positioned on one of the bi directional load station conveyors 5. Note, there are fifteen palletising stations 20 (there are twenty packing lines, however a number of lines will run the same product and therefore can run to shared palletizing stations). In summary, both embodiments include multiple product infeed lines, layer forming shuttles/tables, squaring tables, suitable palletisers, pallet outfeed lines, empty pallet dispensers and pallet shuttles for delivering same to the pallet conveyors. 25 It will be appreciated that while the layer-forming shuttle/table arrangements described and the gripper/forklift arrangement described are suited to the palletising system described, they are equally suited to use in other palletising systems or in other package handling situations. The invention has been described by way of non-limiting example only and many 30 modifications and variations may be made thereto without departing from the spirit and scope of the invention.

Claims (24)

1. A palletising system comprising a multiplicity of infeed lines in parallel array, one or more layer-forming shuttles operable to form layers of packaged goods received from 5 multiple infeed lines in predetermined patterns, means for squaring and compacting each formed layer, and palletising means for transferring each compacted layer to one of a multiplicity of pallets.

2. The palletising system of claim 1, wherein each layer-forming shuttle travels transversely of the array of infeed lines. 10

3. The system of claim 1, further comprising a pickup table arranged at the end of each squaring means, and including means for elevating each compacted layer to allow fork access for transfer by the palletising means.

4. The system of claim 1, 2 or 3, wherein the palletising means includes a gripping head incorporating lifting forks and squaring devices mounted on a robotic arm for 15 gripping a compacted layer from a pickup table adjacent the compacting and squaring means for transfer to a selected one of a multiplicity of pallets.

5. The system of claims 1, 2 or 3, wherein the palletising means comprises a low level palletiser for gripping a compacted layer from the compacting and squaring means for transfer to a selected one of a multiplicity of pallets. 20

6. A method of palletising packaged goods comprising the steps of receiving packaged goods from a multiplicity of conveyor infeed lines, aligning a layer-forming table with one of said infeed lines to receive packaged goods for the formation of a layer according to a predetermined pallet pattern, moving the loosely assembled layer to a squaring table for squaring and compaction, moving the squared and compacted layer to a predetermined one 25 of a multiplicity of pallets, and then repeating the process for each of the multiplicity of infeed lines until a predetermined number of pallets have been completed.

7. The method of claim 6, wherein the layer-forming table is moveable transversely of the multiplicity of infeed lines to allow alignment with each of the infeed lines as dictated P OPER\TNB\SPEC\306%84 Improv nt in Palleising Sysms Specidoc-9/12/2008 - 27 by a suitable control system.

8. The method of claim 6 or 7, comprising moving two or more layer-forming tables transversely to each of a selected number of infeed lines.

9. The method of any one of claims 6 to 8, wherein the squared and compacted layer is 5 transferred using a gripper or other palletising device, the squared and compacted layer being delivered to a pickup table having means for elevating the layer to enable the penetration of forks or the like under the layer for transfer of the layer to a pallet.

10. The method of any one of claims 6 to 9, wherein the squaring step ensures that the packed goods are properly aligned to allow the assembly of stacks or columns of the 10 packed goods with locating tabs ensuring proper location of each package with respect to the others.

11. A control system for a palletising system having a multiplicity of packaged product infeed lines and a multiplicity of pallet load stations, said control system including line allocation means for allocating packaged product from a particular infeed line to a 15 particular pallet load station.

12. The system of claim 11 further including product line control means, such as a touch-panel, which indicates the required product stack height for the next palletising operation as well as the number of stacks required.

13. The system according to claim 11 or 12, wherein the line allocation means may be 20 operated by a "mouse dragging" operation from a selected line indicator to the required pallet load station.

14. The system of any one of claims 11 to 13, wherein the system includes a profile change process which allows a line allocation to be changed while the system is running.

15. A mechanism for orienting packaged goods to allow the formation of layers suitable 25 for palletising, comprising driven rollers for supporting and transferring a package, package orienting means nested between the rollers and mounted for elevation and rotation to achieve package orientation, the driven rollers being mounted for lateral movement to PVPER\TNB\SPEC\3O6% 44 Improvnnts in Palletising Systns Spccidoc-9/122008 - 28 position the package for transfer to a predetermined position, and package supporting transfer means operable to transfer each package to a predetermined position against a barrier means for accumulation of a layer of packages suitable for palletising.

16. The mechanism of claim 15, wherein the driven rollers, the packaging orienting 5 means and the transfer means are supported on a carriage which is adapted to travel on tracks or the like so as to receive packaged goods from a multiplicity of conveyor infeed lines.

17. The mechanism of claim 15 or 16, wherein the package orienting means comprises of plurality of support elements spaced to nest between adjacent rollers and supported by a 10 central column including means for elevating and rotating the column to change the orientation of a package supported by the elements.

18. The mechanism of any one of claims 15 to 17, wherein the nesting of the elements between the rollers is such that when the elements are lowered between the rollers to their nested position, the rollers engage the package to transfer it to the transfer means for the 15 assembly of a layer of packaged goods.

19. The mechanism of any one of claims 15 to 18, wherein the transfer means is a driven belt.

20. A gripper for mounting on a robotic arm or the like comprising a support structure adapted for attachment to the robotic arm and carrying opposed fork assemblies adapted 20 for movement towards and away from each other to support or release a layer of packaged goods, opposed load squaring plates also mounted on the support structure for movement towards and way from each other to square and align the layer to be transferred by the gripper.

21. The gripper of claim 20 including a pair of additional squaring plates positioned 25 inwardly of the opposed fork assemblies and intermeshed with the forks to allow for squaring of a load before it is palletised.

22. The system of any one of claims 1 to 5, substantially as described with reference to any one or more of the Figures of the accompany drawings. P:OPER\TNB\SPECP\3069644 ImirovemLs in Panctising Synans Speidoc-9/122OOS - 29

23. The method of any one of claims 6 to 10, substantially as described with reference to any one or more of the Figures of the accompany drawings.

24. The system of any one of claims 11 to 14, substantially as described with reference to any one or more of the Figures of the accompany drawings. 5