Method of erecting box for insertion of roll packed mattress

A method of boxing a roll packed mattress for shipment, said method comprising:

• activating a picker actuator and moving the picker actuator from a picker home position to a position above a stack of flattened boxes;
• picking up an uppermost flattened box from the stack with the picker actuator and transporting the uppermost flattened box to a transfer location;
• moving a transport actuator to the transfer location;
• activating suction cups of the transport actuator to grip a bottom surface of the uppermost flattened box;
• moving an erector actuator to a position adjacent to the transport actuator;
• activating suction cups of the erector actuator to grip a top surface of the uppermost flattened box;
• disengaging the picker actuator from the uppermost flattened box and returning the picker actuator to the picker home position;
• moving the erector actuator while the transport actuator remains stationary to erect the uppermost flattened box into an erected box;
• pushing first and second box flaps closed of the erected box using at least one flap closer;
• moving the erected box downstream using the erector and transport actuators simultaneously such that arms fold third and fourth flaps of the erected box closed outside the first and second box flaps to create a partially closed, untaped erected box;
• moving the partially closed, untaped erected box past a tape dispenser which tapes the third and fourth flaps of the untaped erected box together to a create a partially closed box;
• disengaging the transport actuator from the partially closed box and returning the transport actuator to the transport home position;
• moving the partially closed box to a mattress loading station;
• at the mattress loading station placing a roll packed mattress into the partially closed box to create a loaded box having an open end;
• moving the loaded box onto a weighing station using a lift table;
• closing flaps of the open end of the loaded box and applying a center tape seam to create a closed box;
• rotating the closed box and inserting the closed box into a side taping section;
• taping outer edges of the closed box at each end of the closed box to create a finished box;
• and
• transferring the finished box to an offloading table.

A method of boxing a roll packed mattress for shipment, said method comprising:

• activating a picker actuator and moving the picker actuator from a picker home position to a position above an uppermost flattened box of a stack of flattened boxes;
• picking up the uppermost flattened box with the picker actuator and transporting the uppermost flattened box to a transfer location;
• moving a transport actuator to the transfer location;
• activating suction cups of the transport actuator to grip a bottom surface of the uppermost flattened box;
• moving an erector actuator to a position adjacent to the transport actuator;
• activating suction cups of the erector actuator to grip a top surface of the uppermost flattened box;
• disengaging the picker actuator from the uppermost flattened box and returning the picker actuator to the picker home position;
• erecting the uppermost flattened box into an erected box;
• pushing first and second box flaps closed of the erected box using at least one flap closer;
• moving the erected box downstream using the erector and transport actuators simultaneously such that arms fold third and fourth flaps of the erected box closed outside the first and second box flaps to create a partially closed, untaped erected box;
• moving the partially closed, untaped erected box past a tape dispenser which tapes the third and fourth flaps of the untaped erected box together to a create a partially closed box;
• disengaging the transport actuator from the partially closed box and returning the transport actuator to the transport home position;
• moving the partially closed box to a mattress loading station;
• at the mattress loading station placing a roll packed mattress into the partially closed box to create a loaded box having an open end;
• moving the loaded box onto a weighing station using a lift table;
• closing flaps of the open end of the loaded box and applying a center tape seam to create a closed box;
• manually rotating the closed box and inserting the closed box into a side taping section;
• taping outer edges of the closed box at each end of the closed box to create a finished box;
• and
• transferring the finished box to an offloading table.