TECHNICAL FIELD

[0001] The present invention is directed to an apparatus and method for automating the transport and palletisation of posts.

BACKGROUND

[0002] Posts such as star posts (also known as star pickets) are commonly used around the world for fencing and like construction tasks. Such posts may be of varying length and construction. For instance, the star pickets may be made of steel, aluminium, polyvinyl chloride (PVC) or other suitable materials and may be coated in a polymer coating, paint, or galvanised metal (for example, hot dip galvanised, or electrodeposition galvanised) depending on proposed use and material of production. Posts may also include varying features, such as the ground facing end being shaped to a point; or include various holes, flanges, lips, and notches on or along the fins, to provide structural reinforcing and/or enable attachment of fence wire, gate handles, or other fencing attachments within the art. Such variations are merely examples of some of the possible variations which are provided for context to the background of the present invention.

[0003] In Australia, star pickets are commonly manufactured and supplied in the ‘Y-shape’ configuration, while in other countries such as the United States star pickets are commonly supplied in the ‘L-shape’ configuration. In either case, star pickets can be formed of a heavy duty steel material (typically providing a weight of between 1 .7-3.0 kg per metre) at various lengths of between 1.65m to 2.4m, and depending on use may be, for example, painted in matte black or galvanised.

[0004] For supply to retail consumers, posts such as star pickets may be sold in bundles of approximately 10 posts. However, for wholesale or trade transport and supply, posts may be sold in bundles of 200-400 posts. To prepare for bundling and transport, posts are commonly manually handled into bundles which are then tightly bound together with a non-elastic, flexible and frangible material such as plastic, twine or tape and wooden gluts. An example of prior art bundling of star pickets is shown in Figure 9B. By tightly binding the posts together in a bundle, it is hoped that the bundle will maintain a sufficient level of structural integrity to enable it to be stored and transported.

[0005] The handling of products such as posts is commonly understood to be inefficient for large scale production and often results in bottlenecking of the overall factory-line or supply-line efficiency. Further, recent use of longer and heavier posts (e.g. longer and heavier star pickets) creates occupational health and safety risks where manual operators are required to lift and stack 4-5kg posts in a day-in day-out role. These issues can additionally present themselves during processing of posts, such as transport of posts to galvanising or painting facilities wherein transport to process lines may require manual handling. [0006] Existing bundling or stacking arrangements can also present significant safety issues during transport whereby one or more posts may ‘spear’ out of the existing bundle or stack during rapid acceleration or deceleration. That is, one or more posts may ‘spear’ out of the bundle during transport, potentially requiring the posts to be re-bundled in addition to the clear safety issues presented. These dangers can be reduced by providing further and tighter binding of the relevant posts or bundles, however this can involve further resources and materials to tightly bind the relevant stack.

[0007] It would be desirable to therefore provide an apparatus or method which addresses one or more of the above-identified issues. It would further be desirable to enable stacking and transport of posts such as star pickets in a manner that reduces occupational health and safety risks, and/or enables stacking of posts such as star pickets in a manner which can reduce the risk of spearing while reducing binding material requirements.

SUMMARY OF INVENTION

[0008] According to a first aspect of the invention, there is provided an effector for handling a plurality of posts in alignment, the effector comprising: an engagement member for engaging with a plurality of posts arranged in an alignment; and a coupling means for detachably coupling the plurality of posts to the effector while the plurality of posts are engaged with the engagement member, wherein the engagement member comprises an engagement surface shaped to ensure the plurality of posts are in alignment while coupled to the effector.

[0009] In an embodiment, the engagement surface is shaped to conform to the shape of the plurality of posts in alignment.

[0010] In an embodiment, the coupling means comprises a coupling member configured to couple the plurality of posts to the effector.

[0011] In an embodiment, the coupling member is configured to couple the plurality of posts to the effector via magnetic force.

[0012] In an embodiment, the coupling member comprises a magnet.

[0013] In an embodiment, the effector is configured to transfer between: an engaged configuration, in which the coupling member contacts or is proximate to the plurality of posts, and a disengaged configuration, in which the coupling member is distanced from the plurality of posts. [0014] In an embodiment, the coupling member is recessed in relation to the engagement member when the effector is the disengaged configuration.

[0015] In an embodiment, the effector transfers between an engaged configuration and a disengaged configuration via hydraulic or pneumatic means.

[0016] In an embodiment, the engagement surface comprises a series of protrusions, each protrusion having a cross-section configured to conform to the shape of a post in alignment.

[0017] In an embodiment, the engagement surface comprises a plurality of slots, each slot located between neighbouring protrusions.

[0018] In an embodiment, a cross section of each protrusion comprises a substantially triangular tip.

[0019] In an embodiment, the effector is configured for handling a plurality of star pickets in alignment, whereby the engagement surface is shaped to ensure star pickets are maintained in alignment during coupling.

[0020] In an embodiment, the effector is configured for handling a plurality of Y-shaped star pickets in alignment, whereby the engagement surface is shaped to ensure Y-shaped star pickets are maintained in alignment during coupling.

[0021] According to a second aspect of the invention, there is provided an effector for handling a plurality of Y-shaped star pickets in alignment, the effector comprising: an engagement member for engaging a plurality of star pickets; and a coupling member for coupling the plurality of star pickets to the effector, wherein the engagement member comprises an engagement surface shaped to ensure posts are maintained in alignment while coupled to the effector, the engagement surface further comprising: a series of protrusions, a cross section of each protrusion comprising a substantially triangular tip; and a plurality of slots, each slot located between neighbouring protrusions, such that the engagement surface is configured to conform to the shape of star pickets coupled in alignment thereto whether: a fin of each star picket is inserted into a corresponding slot of the engagement surface; or two fins of each star picket overlay a corresponding protrusion of the engagement surface.

[0022] In an embodiment, the coupling member is configured to effect coupling by one or more of magnetic attraction, vacuum, or mechanical gripping. [0023] In an embodiment, the coupling member is configured to effect coupling by magnetic attraction.

[0024] In an embodiment, the effector is configured to transfer between: an engaged configuration, in which the coupling member contacts or is proximate to the plurality of posts, and a disengaged configuration, in which the coupling member is distanced from the plurality of posts.

[0025] In an embodiment, the coupling member is recessed in relation to the engagement member when the effector is the disengaged configuration.

[0026] In an embodiment, the effector transfers between an engaged configuration and a disengaged configuration via hydraulic or pneumatic means.

[0027] According to a third aspect of the invention, there is provided a pick and place robot comprising an effector according to the previous aspects of the invention.

[0028] According to a fourth aspect of the invention, there is provided a method of using the pick and place robot of the third aspect of the invention to handle posts.

[0029] According to a sixth aspect of the invention, there is provided a method of using the pick and place robot of the fourth aspect to handle Y-shaped star pickets.

[0030] In an embodiment, the pick and place robot is used to stack a plurality of Y-shaped star pickets in alignment.

[0031] In an embodiment, the pick and place robot is used to stack a plurality of Y-shaped star pickets in rows alternating between a first row configuration and a second row configuration, such that: in a first-row configuration, a fin of each of the Y-shaped star pickets points substantially vertically upward; and in a second-row configuration, a fin of each of the Y-shaped star pickets points substantially vertically downward.

[0032] In an embodiment, each row having a first-row configuration comprises 10 to 20 Y-shaped star pickets.

[0033] In an embodiment, each row having a first-row configuration comprises 12 Y-shaped star pickets.

[0034] In an embodiment, when the pick and place robot is used to pick up a row of Y-shaped star pickets for a first-row configuration: the pick and place robot approaches the row of Y-shaped star pickets for coupling from above.

[0035] In an embodiment, each row having a second-row configuration comprises 11 to 21 Y- shaped star pickets.

[0036] In an embodiment, each row having a second-row configuration comprises 13 Y-shaped star pickets.

[0037] In an embodiment, when the pick and place robot is used to pick up a row of Y-shaped star pickets for a second-row configuration: the pick and place robot approaches the row of Y-shaped star pickets for coupling from below.

[0038] In an embodiment, following pick up of the row of Y-shaped star pickets for a second-row configuration, the effector is rotated 180° around the x-axis prior to putting down the row of Y- shaped star pickets.

[0039] In an embodiment, the method is used to stack multiple rows of star pickets, such rows alternating between a first-row configuration and a second-row configuration.

[0040] According to a sixth aspect of the invention, there is provided a stack of star pickets produced according to the method of the sixth aspect of the invention.

[0041] According to a seventh aspect of the invention, there is provided a method to stack a plurality of Y-shaped star pickets in rows alternating between a first-row configuration and a second-row configuration, such that: in a first-row configuration, a fin of each of the Y-shaped star pickets points substantially vertically upward; and in a second-row configuration, a fin of each of the Y-shaped star pickets points substantially vertically downward.

[0042] Throughout this specification and the claims which follow, unless the context requires otherwise: reference to like numbers denotes reference to like features; the word "comprise", and variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps; the use of '(s)' following a noun means the plural and/or singular form of that noun. Further, as used herein the term 'and/or' means 'and' or 'or', or where the context allows both; reference to a “member” is not intended to limit the referenced member to an element of unitary construction, and should be understood to include further arrangements such as assemblies of multiple elements. In this way, reference to a member includes reference to an assembly of elements; reference to “a” or “one” thing, includes a reference to “one or more” of that thing; the term “star picket” or “star picket” refers to an elongate post or post typically used for fencing, wherein a star picket is in the form of an elongate member which includes a first fin, a second fin and a third fin extending from a central axis of the elongate member. That is, an end view or cross-sectional view, the start post provides a "Y," "T” or “L” shape. As would be understood by a person skilled in the art, the fins may be arranged at different angles around the central axis relative to one another. To assist the skilled reader in understanding the invention, the three fins have been attributed numerical references. Accordingly, within the context of the specification, the first fin is the vertical fin in the "Y," "T” or “L” shape and the second and third fins are the arms of the "Y," "T” or “L” shape. terms such as "side," "end," "top," "bottom," and the like are only used to describe elements as they relate to one another but are in no way meant to recite specific orientations of the device, to indicate or imply necessary or required orientations of the device, or to specify how the invention described herein will be used, mounted, displayed, or positioned in use; and the reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

BRIEF DESCRIPTION OF FIGURES

[0043] The present invention is described by way of non-limiting examples within the following description and figures. To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the present invention will suggest themselves without departing from the scope of the present invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting. Where specific integers are mentioned herein, which have known equivalents in the art to which this invention relates; such known equivalents are deemed to be incorporated herein as if individually set forth.

[0044] Figure 1 shows an exploded view of an effector according to an embodiment of the invention.

[0045] Figure 2 shows a close up exploded view of a coupling member forming part of the effector of Figure 1 .

[0046] Figure 3 shows the effector of Figure 1 , at various angles.

[0047] Figure 4 shows the effector of Figure 1 being used to transfer and layer rows of Y-shaped star pickets according to an embodiment of the invention. [0048] Figure 5 shows a robot incorporating the effector of Figure 1 being used to pick up a row of Y-shaped star pickets to lay down in a first-row configuration according to an embodiment of the invention.

[0049] Figure 6 shows a robot incorporating the effector of Figure 1 being used to pick up a row of Y-shaped stay pickets to lay down in a second-row configuration according to an embodiment of the invention.

[0050] Figure 7A shows a stack of Y-shaped star pickets according to an embodiment of the invention, set out in alternating rows whereby a first row is provided in a first-row configuration and a second row is provided in a second-row configuration.

[0051 ] Figure 7B shows a stack of Y-shaped star pickets according to the prior art.

[0052] Figure 8 shows a stack of Y-shaped star pickets strapped together in a strapping configuration with 3 Straps and 3 Top Timbers, according to an embodiment of the invention.

[0053] Figure 9 shows a stack of Y-shaped star pickets strapped together in another strapping configuration, with 4 Straps and Nil Top Timbers, according to an embodiment of the invention.

[0054] Figure 10 shows a stack of Y-shaped star pickets strapped together in another strapping configuration with 4 Straps and 2 Top Timbers, according to an embodiment of the invention.

List Of Parts

1 Effector

2 Robot

3 Engagement member

4 Engagement surface

5 Engagement protrusions

6 Engagement slots

7 Coupling member

8 Coupling surface

9 Coupling protrusions

10 Coupling slots

11 Central coupling bar

12 Magnet

13 Effector Frame

14 Push piston

15 Linear Guide Female

16 Valve

17 Robot Mount

18 Actuator 19 Star pickets in first-row configuration

20 Star pickets in second row configuration

21 Conveyor

22 Pellet

DETAILED DESCRIPTION

[0055] In broad terms, the present invention provides an effector for a pick and place robot, the effector suitable for transporting posts (such as Y-shaped star pickets) in alignment. Within the broader inventive concept, various embodiments of an effector and method for using said effector are described and defined in further detail below. While in certain embodiments, an effector may be configured to stack a plurality of posts on a pallet for packaging, it is to be understood that the invention is not so limited and that an effector may more generally be used for transport of elongated objects such as posts of other designs and configurations. In other embodiments, the present invention relates to a stack of Y-shaped star pickets having a particular configuration.

[0056] Referring to Figure 1 to Figure 3, an effector 1 according to certain embodiments is shown which may be mounted to a pick and place robot 2 for handling a plurality of star pickets in alignment, including for stacking star points in alignment into a pallet.

[0057] In the embodiment shown, the effector 1 comprises two engagement members 3 configured to engage with star pickets arranged in alignment. Each engagement member 3 comprises an engagement surface 4 configured to contact and engage with posts in alignment. The precise configuration of an engagement surface will depend on the configuration of the posts it is designed to handle. In the embodiment shown, the engagement surface 4 is configured to handle Y-shaped star pickets, and the engagement surface 4 in turn comprises a series of protrusions 5 separated by slots 6. In other embodiments, an engagement surface may be configured to contact T-shaped star pickets or L-shaped star pickets, in which case the engagement surface may still comprise a series of protrusions separated by slots, however the protrusions may be of generally square or rectangular cross-section (as opposed to having a cross section with a generally triangular tip as shown). In other embodiments, an engagement surface may be configured to contact cylindrical posts, in which case the engagement surface may comprise a series of elongate recesses of semicircular cross-section, each recess configured to engage the outer surface of a cylindrical post.

[0058] As noted above, the currently exemplified effector 1 is configured to engage and handle Y-shaped star pickets. As will be understood in the art, a Y-shaped star picket comprises three fins extending along its length, adjoining fins separated by 120°. To correspond to the shape of the Y-shaped star picket, a cross-section of each protrusion 5 is shown as comprising a generally triangular tip with a point angle of at or around 120° so that two adjoining fins of a Y-shaped star picket may each engage the protrusion 5 in use. Neighbouring protrusions 5 are separated by a slot 6, the slot 6 configured to house a fin of a Y-shaped star picket. [0059] According to certain embodiments of the invention, while an engagement member is arranged to engage with and ensure posts are in alignment, the effector may further comprise a coupling member to couple with posts while the posts are engaged in alignment with the engagement member. In alternative embodiments, an effector may not require a coupling member. For example, the effector may comprise an engagement member that may itself enable coupling (and decoupling) of posts, such as where the engagement member may be selectively magnetised using electromagnetism. Alternatively, the engagement member may internally comprise a vacuum system for coupling posts via vacuum (requiring additional items such as vacuum pumps, compressed air, pneumatic tubing and solenoid valves). Nevertheless, in certain embodiments the coupling member may comprise a coupling surface configured to contact and couple with the posts while engaged by the engagement member. In certain embodiments the shape of the coupling surface may generally correspond with the shape of the posts in alignment. In further embodiments the coupling surface may generally correspond in shape with the shape of the engagement surface of the engagement member. In this way, where for example the effector is designed to pick up cylindrical posts, the coupling surface may comprise a series of elongate recesses of semicircular cross-section, each recess configured to engage the outer surface of a cylindrical post. Where the effector is provided to pick up Y-shaped star pickets (as is the case in the embodiment shown in Figure 1 to Figure 3), the coupling surface 8 may comprise a series of protrusions 9 separated by slots 10, whereby the fin of a Y-shaped star picket may be located within a slot 10 intermediate adjacent protrusions 9. Further, a cross-section of each protrusion 9 may comprising a generally triangular tip with a point angle of at or around 120° so that two adjoining fins of a Y-shaped star picket may each contact and couple with the protrusion 9.

[0060] It should therefore be apparent that the effector 1 exemplified in Figure 1 to Figure 3 is capable of engaging Y-shaped star pickets in different configurations of alignment, whereby: in a first-row configuration 19, a fin of each of the star pickets is held within a corresponding slot of the engagement surface (see Figure 4C and 4D); and in a second-row configuration 20, two fins of each star picket contact and overlay a single protrusion at its triangular tip (see Figure 4H and Figure 4I).

[0061] As discussed further below with reference to Figure 4, that the effector of Figure 1 to Figure 3 enables Y-shaped star pickets to be engaged in two different alignments advantageously enables production of a highly stable stack of Y-shaped star pickets quickly and simply. That is, Y-shaped star pickets may be stably stacked using an effector according to embodiments of the invention in a manner reducing the risk of spearing, while also reducing the amount of binding materials required.

[0062] According to certain embodiments, the coupling surface may hold fast to posts via one or more of magnetic attraction (permanent or electromagnetic), vacuum, or mechanical gripping. In the embodiment shown in Figure 1 to Figure 3, Y-shaped star pickets are coupled via magnetic attraction. To enable this, the exemplified coupling member ? comprises magnets 12 embedded into the coupling surface 8, thereby enabling the coupling member 7 to couple with iron or steel star pickets when the coupling member 7 is in contact with or proximate to the star pickets.

[0063] According to embodiments involving a permanent magnet, the effector may be configured to transfer between: an engaged configuration, in which the coupling member contacts or is proximate to the plurality of posts, and a disengaged configuration, in which the coupling member is distanced from the plurality of posts. This may be enabled by for example enabling the coupling member to move relative to the engagement member or vice versa, as now exemplified with reference to Figure 1 to Figure 3.

[0064] As shown in Figure 1 to Figure 3, the exemplified effector 1 comprises a coupling member 7 formed of an assembly as now described. The coupling member 7 comprises a central coupling bar 11 onto which a plurality of protrusions 9 are attached. In Figure 1 to Figure 3, 14 protrusions 9 are attached to the central coupling bar 11. As shown, the protrusions 9 comprise a cross section ending in a generally triangular tip corresponding to the angle between adjacent fins of a Y-shaped star picket. Within the angled surface of the protrusion 9 located each side of the generally triangular tip (forming part of the coupling surface 8 of the coupling member 7) is embedded a permanent magnet 12 as described above. Between each protrusion 9 is located a slot 10 configured to enable a fin of a Y-shaped star picket to be located therein as described above. The assembly of the central coupling bar 11 and protrusions 9 with embedded magnets 12 forms a coupling member 7, with the exemplified effector 1 comprising two coupling members 7.

[0065] To enable each coupling member 7 to transfer between an engagement position (in which the coupling members 7 will couple to Y-shaped star pickets engaged by the engagement members 3) and a disengagement position (in which the coupling members 7 will be distanced from, and not engage, the Y-shaped star pickets), the coupling member 7 has four push pistons

14 attached thereto. These push pistons 14 are arranged to slide through respective linear guides

15 to enable the coupling member 7 to translate up and down relative the effector frame 13. Such movement is powered pneumatically via actuator 18. Other configurations are of course envisaged whereby, for example, the engagement member is transferred between engagement and repositions mechanically rather than pneumatically. Likewise, other embodiments are envisaged in which, engagement and disengagement of a coupling member is achieved by configuring the engagement member to move relative the coupling member. That is, the engagement member moves between a retracted position enabling contact between the coupling surface and a star picket, and an extended position enabling separation between the coupling surface

[0066] Thus, according to the embodiment shown in Figure 1 to Figure 3, to pick up a row of Y- shaped star pickets in alignment (as described in greater detail below with reference to Figure 4), the effector 1 is located such that the engagement member 3 engages with the row of Y-shaped star pickets and the coupling member 7 is then transferred from a disengaged position where the coupling member is distanced from the engagement surface 4 (and in turn the row of Y-shaped star pickets - see for example Figure 4B) to an engaged position where the coupling surface 8 is aligned with the engagement surface 4 (enabling contact or close proximity between the magnets 12 embedded in the protrusions 9 and the Y-shaped star pickets - see Figure 4C). Similarly, to put down a row of Y-shaped star pickets the coupling member 7 is transferred from an engaged position to a disengaged position where the Y-shaped star pickets are separated from the coupling member 7 by the engagement member 4 (which in turn ensures that the Y-shaped star pickets remain in alignment following disengagement).

[0067] The effector 1 exemplified in Figure 1 to Figure 3 is configured to handle a row of up to 13 Y-shaped star pickets of up to 2700mm length. This is demonstrated in Figures 4A to Figure 4D, where a row of 13 star pickets, totalling approximately 110kg, is shown being picked up by the same effector 1 . Figure 4A shows a robot 2 lowering the effector 1 into position on the row of star pickets which has been formed on an indexing belt. Once lowered, an upper fin of each star picket enters a corresponding slot 6 of the engagement member s as shown in Figure 4B. Actuators 18 then lower the coupling member 7 onto the star pickets as per Figure 4C, thereby securing the star pickets to the coupling surface 8 by magnetic attraction. As shown, the star pickets are thereby in a first-row configuration 19 whereby a fin of each star picket is engaged within a corresponding slot 6 of the engagement surface 8.

[0068] Figure 4D to Figure 4G show a method for placing a row of star pickets in a first-row configuration onto a pallet. The robot may position the row either onto the newly laid dunnage, as per Figure 4E, or alternatively onto existing rows of star pickets when forming subsequent rows. Once in position at the delivery location the actuators 18 retract the coupling surface 8, thereby enabling the engagement member 3 to disengage the row of star pickets from the coupling surface 8 while maintaining the alignment of the star pickets as per Figure 4F. Once the engagement surface 8 is fully retracted and the star pickets disengaged, the effector 1 can move free of the row of star pickets, with a fin of each of the star pickets pointing substantially vertically upward in a first-row configuration 19, as per Figure 4G. The effector 1 can then return to the indexing conveyor to handle further rows of star pickets as now described.

[0069] Figure 4H to Figure 4L show a method for handling a plurality of star pickets for to provide a second row of star pickets above that just placed. Referring to Figure 4H, once a complete row of star pickets has formed on the indexing belt, the robot 2 can move the effector 1 into position by approaching the star pickets from below, between the indexing conveyor. The row shown has 12 star pickets, totalling approximately 100kg. Two fins of each star picket overlay a corresponding protrusion 5 of the engagement members in a second-row configuration, as shown in Figure 4I. Once in position, the actuators 18 extend the coupling surface 8 to the star pickets, with the shape of the coupling protrusions 9 corresponding to adjoining fins of the star pickets, so as to secure the star pickets to the effector 1 in alignment as per Figure 4J. [0070] Referring to Figure 4K, the robot 2 transfers the plurality of star pickets from the indexing conveyor and rotates 180° around the x-axis (i.e. ‘flips over’), to invert the second row of star pickets in a second-row configuration, which may then be applied atop the earlier row (the earlier row being in a first-row configuration 19).

[0071] Figure 4K to Figure 4M show a row of star pickets in a second-row configuration being placed onto a pallet according to certain embodiments. The robot 2 will lower the row of star pickets in a second-row configuration so that fins are positioned between the star pickets of the existing row in a first-row configuration 19, per Figure 4K. Once so positioned, the actuators 18 retract the coupling surface 8, enabling the engagement member 3 to disengage the star pickets from the coupling surface 8. Once the coupling surface 8 is retracted, the effector 1 can move free of the row of star pickets, and then return to the indexing conveyor to repeat the process of Figure 4. In an embodiment, this process is repeated until the stack of star pickets is complete and moves clear of the palletising area.

[0072] The overall result of the method shown is that star pickets are stacked in a manner which improves the overall efficacy of the packing and quality of the final stacked product. In particular, star pickets are stacked in a manner which increases overall surface contact between star pickets to thereby increase friction and stability of the stack and reduce the likelihood of spearing and general stack disengagement.

[0073] Figure 5A and Figure 5B show an effector 1 connected to a robot 2 (via robot mount 17) picking up a row of Y-shaped star pickets from a conveyor 21 and placing the row onto a pellet 22 for bundling.

EXPERIMENTS

[0074] A proposed star picket stacking pattern in accordance with the above teaching was assessed for stability against several strapping configurations.

[0075] Assessment of star picket packing arrangements to achieve the most suitable combination of overall technical and practical performance per pack type, were tested with the following parameters:

Several different strapping configurations in accordance with the invention were assessed against a control packs in an existing packing arrangement (for baseline comparison);

1650mm Black Star pickets (part number 160003) were utilised in assessment, given they are a suitably representative high-volume product; assessment criteria were determined based on customer and vendor requirements. Packing Configuration

[0076] Both the proposed profiles (according to embodiments of the invention - see Figure 9A) and existing-known profiles (see Figure 9B) of star picket packing arrangements were assessed. The specifics of each packing profile follow.

Proposed Pack Profile

The key features of a proposed pack profile according to an embodiment of the invention are shown at Figure 7A, the pack profile comprising:

Inverted rows of star pickets with ten rows of 17 each, and two rows of 15 each;

No intermediate timber slabs; and No taped sub-bundles.

Existing Pack Profile

The key features of an example existing pack profile are shown at Figure 7B, which comprises: Sub-bundles of four star pickets in three rows of 13 sub-bundles, and one row of 11 subbundles;

Intermediate timber slabs between rows of sub-bundles; and Taped sub-bundles at each end of each sub-bundle.

Strapping

[0077] Several strapping configurations for the proposed pack arrangement were tested. The existing pack arrangement (i.e. see Figure 7B) was sampled for baseline purposes. Details of the strapping arrangements tests are compiled per the indexed summary in Table 1 below, and displayed with sketches in Figures 8-11 :

Table 1. Configuration Index

Test Results

[0078] Test results were collated in standardised format to ensure direction comparison was possible. Data was captured across the following categories:

Serialised Configuration; Tilt Testing;

General Pack Performance;

Strap Tension; and

Stacking.

Serialised Configuration

[0079] Two serialised packs of each configuration were produced to satisfy both ‘tilt-then- dynamic’, and ‘warehouse (static)’ test scenarios.

[0080] The ‘tilt-then-dynamic’ test represented initial controlled tilt tests to a specified 40° angle, followed by practical on-truck transit of the same packs. Packs themselves were transited interstate and then returned to the original factory some weeks later for assessment of performance. Each pack was initially stacked as the bottom of three packs on the truck to represent worst-case loading.

[0081] The warehouse (i.e. static) test represented a controlled study of pack performance per standard warehouse logistics movements and handling. The packs themselves were handled by common practice within the warehouse for several weeks prior to assessment. This included fork truck movements, stacking, and general warehouse interactions.

[0082] Identification of the test star picket packs, allocated by specific serial number, are shown in Table 2 below:

Table 2: Test Pack Serial ID

Tilt Testing

[0083] Tilt testing of each pack configuration was conducted at an angle greater than 38° (nominally 40°), longitudinally to the length of star pickets. A single pack of each configuration only was tested. The lower end glut (following tilting) was rested against the tilt jig. A single lashing ratchet strap was secured over the centre of the strapped star picket pack, simulating loading, and securing functions when transited via truck bed. A successful test pass was only afforded if the entirety of each pack did not shift throughout the duration of the tilting process.

[0084] All pack configurations successfully met the tilt test requirements, as summarised in Table 3 below. The corresponding ratchet strap lashing tension per test is also noted for reference.

Table 3: Tilt Test Summary

Strap And Glut Movement - Dynamic Testing

[0085] A summary of pack dimensional performance and general notes associated with each specific pack for dynamic testing purposes is detailed in Table 4 below.

Table 4: Pack Performance - Dynamic Testing

[0086] It can be seen that within the scope of measurement for such non-uniform product, there was negligible difference between prior art configuration and test configuration results.

Strap And Glut Movement - Warehouse Testing

[0087] A summary of pack dimensional performance and general notes associated with each specific pack for warehouse testing purposes is detailed in Table 6 below.

Table 5: Pack Performance - Warehouse Testing

[0088] It can be seen that within the scope of measurement for such non-uniform product, there was negligible difference between prior art configuration and test configuration results.

Strap Tension - Dynamic Testing

[0089] A summary of the strapping tension associated with each specific pack for dynamic testing purposes is detailed in Table 7 below:

Table 6: Strap Tension Comparison - Dynamic Testing

[0090] Initial strapping tension of each pack was achieved to at least a minimum equivalent tension of 117kg per strap, across the range of test packs. In most instances, strapping tensions were noted to be significantly greater than this minimum, up to maximum of 231 kg.

[0091] All packs saw reduction in strap tension star picket-test. In some instances, strap tension was reduced to zero. Of the star picket-test non-zero tension results, the largest percentage reduction in strap tension was 82 percent.

Strap Tension - Warehouse Testing

[0092] A summary of the strapping tension associated with each specific pack for warehouse testing purposes is detailed in Table 8 below:

Table 7: Strap Tension Comparison - Warehouse Testing

[0093] Initial strapping tension of each pack was achieved to at least a minimum equivalent tension of 111 kg per strap, across the range of test packs. In most instances, strapping tensions were noted to be significantly greater than this minimum, up to maximum of 225kg.

[0094] All packs saw reduction in strap tension star picket-test. In some instances, strap tension was reduced to zero. Of the star picket-test non-zero tension results, the largest percentage reduction in strap tension was 74 percent.

Stacking Comparison

[0095] Stacking comparison was only required for the warehouse test regime. Table 9 below identifies the gross mass that was applied atop of each specified pack within the warehouse. The mass of 2750kg represents five total packs of 1650mm long Black Star pickets, each weighing 550kg. This stacking scenario represents the worst-case static load.

Table 8: Stacking Comparison - Warehouse Testing

[0096] No adverse static strength related items were noted on any of the pack configurations. All pack configurations maintained their dimensional profiles and had no adverse effect on the stability of the total stack of packs.

[0097] Further, no adverse warehouse-based logistics performance was noted for any pack configuration.

Test Results

[0098] Specific assessment was afforded to the test categories; tilt testing, general pack performance, strap tension, stacking.

[0099] All allocated pack configurations passed initial tilt testing requirements to a nominal angle of 40°. These packs were then allocated for further dynamic truck testing. [0100] All pack configurations retained their initial pack dimensional profiles following testing. Only a single pack returned from testing with zero strap tension - the prior art pack configuration per static testing, likely as a result of mechanical handling impact. Further, all packs were shown to have significantly lower strap tension star picket-testing. To ensure tilt performance and retainment of pack dimensional profiles in countering an inevitable loss of strap tension, a greater number of straps per pack has been determined to be beneficial. However, this does not alter the fundamental result that a star picket stacking configuration according to embodiments of the invention was shown to be highly stable whereby star pickets were unlikely to spear notwithstanding reduced binding requirements.

[0101] The effect of static warehouse stacking was shown to be non-discernible across the range of tested pack configurations. All pack configurations performed positively and as expected when stacked under worst-case load arrangements. Pack configurations with addition of top timbers did not offer any obvious benefit per the stacking scenarios.

[0102] It was therefore identified that the existing pack configuration had no marked benefits over the proposed pack, notwithstanding the new pack configuration has lower strapping I binding requirements.

Conclusion

[0103] Consisting of the required newly proposed packing configuration, the new strapped arrangement incorporates simplicity via reduction in strapping I binding items required. Both top and intermediate timbers are also no longer required. Placement of four straps drives less reliance on individual strap tension to safely retain the overall bundled configuration.

[0104] Both static and dynamic performance of this pack arrangement was shown to be comparable or better than the existing prior art / control pack configuration.

[0105] In conclusion, embodiments of the present invention provides a simpler and safer way to stack posts such as star pickets, and also enables posts to be stacked in a stable fashion while requiring less binding and supports such as wooden gluts.