Automatic random box sealer and method of sealing boxes of different sizes

A box sealer comprising:

• (a) a first box measurer including a top flap engager movable downwardly from a disengaged position at a box measuring position to an engaged position such that the top flap engager can engage at least one of four upright open top flaps of a box at the box measuring position, the first box measurer including an inductive positioning system;
• (b) a second box measurer including a plurality of centering arms movable inwardly from disengaged positions adjacent to the box measuring position to engaged positions such that the centering arms can engage opposing sides of the box at the box measuring position, the second box measurer including an ultrasonic sensor attached to one of the centering arms;
• (c) a flap closer;
• (d) a tape applicator;
• (f) a conveyor system including a first conveyor configured to move the box to the box measuring position and a second conveyor configured to move the box under the flap closer and the tape applicator;
• and
• (e) a control system that at least partially controls the conveyer system, the first box measurer, the second box measurer, the flap closer, and the tape applicator, the control system configured to receive signals from the first box measurer and the second box measurer to determine the height of the box.

A method of sealing a box having two spaced-apart end central walls connected to two spaced-apart side central walls, two spaced-apart end bottom flaps, two spaced-apart side bottom flaps, two spaced-apart end top flaps, and two spaced-apart side top flaps, said method comprising:

• (a) positioning the box at a box measuring position with the bottom flaps of the box in closed positions and the top flaps of the box in upright open positions;
• (b) moving a top flap engager downwardly from a disengaged position above the box to an engaged position in which the top flap engager engages edges of at least one of the upright open top flaps;
• (c) determining a height of the box partly based on an amount the top flap engager moves downwardly to engage the at least one of the upright open top flaps;
• (d) positioning the box at a box closing position, positioning a flap closer at a position above the box based on the determined height of the box, and causing the flap closer to close the upright open top flaps of the box;
• and
• (e) positioning the box at a box sealing position, positioning a tape applicator at a position above the box based on the determined height of the box, and causing the tape applicator to seal the closed top side flaps of the box.