Stretch-wrapping machine having a roping assembly including a movable tilted film guide

Abstract

Various embodiments of the present disclosure provide a stretch-wrapping machine having a movable titled film guide configured to engage and cause part of a film to be manipulated into a rope form.

Description

STRETCH- WRAPPING MACHINE HAVING A ROPING ASSEMBLYINCLUDING A MOVABLE TILTED FILM GUIDEPriority

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 512,987, filed July 11, 2023, the entire contents of which is incorporated herein by reference.Field

[0002] The present disclosure relates to a stretch-wrapping machine, and more particularly to a stretch-wrapping machine that includes a roping assembly having a movable tilted film guide configured to manipulate a film into a reduced-width rope form to secure a load of goods to a pallet.Background

[0003] Several types of stretch-wrapping machines use stretch film to secure loads of goods on pallets. These str etch- wrapping machines include a film roll carriage configured to support a removable stretch film roll. Such stretch-wrapping machines are configured to rotate the film roll carriage relative to the load while vertically moving the film roll carriage relative to the load to wrap the load in a spiral pattern with the stretch film taken from the film roll.

[0004] When palletized loads are wrapped, it is beneficial to wrap the film around the base of the load and a top portion of the pallet supporting the load to secure the load to the pallet. It is also beneficial to manipulate the film at a bottom area of the film before applying it to the base of the load and the top portion of the pallet. This manipulation of the film is often referred to as roping. This manipulation of the film creates a reinforced area of the film that is more resistant to breakage such as from sharp areas of the pallet.Summary

[0005] Various embodiments of the present disclosure provide a stretch-wrapping machine including a roping assembly having a movable tilted film guide configured to manipulate a film to include a reduced-width rope form before applying part of the film to a base of a load and a top portion of a pallet to secure the load to the pallet.Brief Description of the Figures

[0006] Figure l is a perspective view of a stretch-wrapping machine of one example embodiment of the present disclosure.

[0007] Figure 2 is a block diagram showing certain components of the stretchwrapping machine of Figure 1.

[0008] Figure 3A is a perspective view of a film carriage of a wrapping assembly of the stretch-wrapping machine of Figure 2A showing a roping assembly thereof having a movable tilted film guide in a retracted configuration.

[0009] Figure 3B is a perspective view of the film carriage of Figure 3 A showing the movable tilted film guide in an extended configuration.

[0010] Figures 4A and 4B are top views of the film carriage of Figure 3 A respectively showing the movable tilted film guide in the retracted and extended configurations.

[0011] Figures 5A and 5B are enlarged side views of the movable tilted film guide removed from the film carriage and respectively in the retracted and extended configurations.

[0012] Figures 6A and 6B are top diagrammatic views of a load on a pallet, and the movable tilted film guide removed from the film carriage and respectively in the retracted configuration not engaging the film and in the extended configuration guiding the film toward the load on the pallet.

[0013] Figures 7A and 7B are side diagrammatic views of the load on the pallet, and the movable tilted film guide removed from the film carriage and respectively in the retracted configuration not engaging the film and in the extended configuration guiding the film toward the load on the pallet.Detailed Description

[0014] While the systems, devices, and methods described herein may be embodied in various forms, the drawings show, and the specification describes certain exemplary and nonlimiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connections of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as mounted, connected, etc., are not intended to be limited to direct mounting methods but should be interpreted broadly to include indirect and operably mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

[0015] Figures 1-7B show certain parts of a stretch-wrapping machine 1 (sometimes referred to herein as a “wrapping machine” for brevity) of one example embodiment of the present disclosure. The wrapping machine 1 includes a wrapping-machine frame 10, a circular guide 20, a guide actuator 30, a wrapping assembly 40, a cutting-and-fixing device (not shown), an operator interface 50, and a controller 60.

[0016] The wrapping-machine frame 10 is formed from multiple tubular and / or solid members (not individually labeled) and configured to support the other components of the wrapping machine 1. The wrapping-machine frame 10 defines a wrapping area within its interior and has an infeed area 10a at which a palletized load (such as a load L on a pallet P) is conveyed (such as via a conveyor C) into the wrapping area for wrapping and an outfeed area 10b at which the palletized load is conveyed (such as via the conveyor C) from the wrapping area after wrapping.

[0017] The circular guide 20 serves as the mount for the wrapping assembly 40 and is movably mounted to the wrapping-machine frame 10 (such as to one or more vertical members of the wrapping-machine frame 10) such that the circular guide 20 is verticallymovable relative to the wrapping-machine frame 10 between an upper position and a lower position.

[0018] The guide actuator 30 is operably connected to the circular guide 20 to move the circular guide 20 relative to the wrapping-machine frame 10 between the upper and lower positions. The guide actuator 30 includes one or more motors (not shown) operably connected to the circular guide 20 via one or more belt-and-pulley assemblies (not shown) to move the circular guide 20 between the upper and lower positions. The guide actuator could alternatively include one or more pneumatic or hydraulic cylinders (not shown) operably connected to the circular guide 20 to move the circular guide 20 between the upper and lower positions. The guide actuator 30 is operable under control of the controller 60.

[0019] The wrapping assembly 40 is movably mounted to the circular guide 20 such that the wrapping assembly 40 is rotatable relative to the circular guide 20. The wrapping assembly 40 includes a ring-shaped support (not shown), a fdm carriage 100, a roping assembly 200 supported by the film carriage, and a wrapping-assembly actuator 45.

[0020] The ring-shaped support serves as the mount for the film carriage 100 and is movably mounted to the circular guide 20 such that the support (and the carriage and other components connected to the support) is rotatable relative to the circular guide 20. The support is movably mounted to the circular guide 20 via multiple spaced-apart rollers (not shown) that are connected to the support and positioned on a track (not shown) on the circular guide 20.

[0021] The film carriage 100 is fixedly connected to the support to move with the support (i.e., rotate relative to the circular guide 20 and move vertically relative to the wrappingmachine frame 10). The film roll carriage 100 is configured to rotatably support a film roll (such as a plastic stretch film roll R shown in Figures 4A and 4B). The film carriage 100 includes a film-carriage frame 105 and spaced apart film-reel supports 110a and 110b connected to the frame 105. The film supports 110a and 110b are configured to removably hold the film roll R.

[0022] The film carriage 100 supports the roping assembly 200 in a manner that enables the roping assembly 200 to selectively engage the film. In the retracted configuration, the roping assembly 200 does not guide the film that is pulled off of the film roll R to first positions around the load (such as shown in Figure 7A). In the extended configuration, the roping assembly 200 guides the film that is pulled off of the film roll R to second positions such that a bottom portion of the film is at an elevation below a top portion of a pallet P supporting the loadL (such as shown in Figure 7B). This causes the film to wrap around the base of the load L and the top of the pallet P to better secure the load L to the pallet P, thereby reducing the potential for the load L to shift on the pallet P during transport. In the extended configuration, the roping assembly 200 is also configured to cause a part of the film positioned below the top of the pallet to be formed into a rope-like structure (that is referred to herein as a “rope form” for brevity) and then wrapped around the pallet P. The rope form is a portion of the film that can be concentrated in a compacted manner such as a tightly compacted manner. The rope form can also extend about the top of the pallet onto the load in various embodiments.

[0023] The film carriage 100 also includes various components (not labeled) that direct (and stretch) the film from the film roll R to the guide roller 120 (that directs the film F adjacent to the roping assembly 200) and that are connected to and supported by the filmcarriage frame 105. These components are not described herein for brevity. The film F is drawn off the roll R and directed by and through these components of the film carriage 100 in a downstream direction D. As used herein, “downstream” means the direction of travel of the film F as the film F is pulled off the film roll R and “upstream” means the direction opposite the direction of travel of the film F as the film F is pulled off the film roll R.

[0024] The roping assembly 200 in this example embodiment includes a movable tilted film guide 210, a support member 215, a base 220, and an actuator 230.

[0025] The movable tilted film guide 210 is connected to the support member 215 such that the movable tilted film guide 210 is movable with the support member 215 relative to the carriage frame 105. In this example embodiment, the movable tilted film guide 210 is cylindrical, although it can be alternatively configured. In this example embodiment, the movable tilted film guide 210 is tubular, although it can be alternatively configured. In this example embodiment, the movable tilted film guide 210 includes an outer film engaging surface (not labeled). In this example embodiment, the movable tilted film guide 210 is not configured to rotate. In other example embodiments, the movable tilted film guide 210 is configured to rotate about its own longitudinal axis, and in certain such embodiments can be freely rotatable. In this example embodiment, the movable tilted film guide is not pivotable or otherwise configured to pivot or move (except from the retracted configuration to the extended configuration). In this example embodiment, the angle of the tilted film guide 210 is fixed relative to the support member 215 and relative to the film F. In this example embodiment, the angle of the movabletilted film guide 210 is fixed relative to the actuator 230 that moves the tilted film guide 210 from the retracted configuration to the extended configuration. In this example embodiment, the movable tilted film guide 210 is not pivotable relative to the actuator 230 that moves the tilted film guide 210 from the retracted configuration to the extended configuration. In this example embodiment, the movable tilted film guide 210 is movable from the retracted configuration to the extended configuration at a transverse angle to the film. In this example embodiment, the movable tilted film guide 210 is movable from the retracted configuration to the extended configuration at a perpendicular angle to the film. In this example embodiment, when the movable tilted film guide 210 is in the retracted configuration, it is in a retracted position and does not engage the film. In this example embodiment, when the movable tilted film guide 210 is in the extended configuration, it is in an extended position and engages the film.

[0026] More specifically, the movable tilted film guide 210 is fixed at a downward angle from its top end (not labeled) to its bottom end (not labeled). In various example embodiments, the movable tilted film guide 210 is tilted at an angle ranging from approximately 5 degrees through approximately 45 degrees offset from a vertical axis (not shown). The angle of tilt can vary based on one or more factors such as but not limited to: (1) the width of the film; (2) the size of the pallet and load; (3) the size of the wrapping assembly; (4) the desired amount of the rope form at the bottom of the film; (5) amounts of friction caused by the various components; (6) film tension levels; and / or (7) film feeding speeds. As indicated above, when the movable tilted film guide 210 is in a retracted position, it is positioned and otherwise configured to not engage and thus not direct the film F onto the load L (as best shown in Figures 5 A, 6A, and 7A). As also indicated above, when the movable tilted film guide 210 is in an extended position, it is positioned and otherwise configured to engage and thus direct the top edge of the film F downwardly along the tilted film guide 210 and onto the load L and the pallet (as best shown in Figures 5B, 6B, and 7B) as further described below. This downward direction of the film along the length of the tilted film guide cause the rope form to be created at the bottom of the film.

[0027] The support member 215 is connected to and supported by the actuator 230. The support member 215 extends transversely and upwardly from the actuator 230. The support member 215 includes a plurality of suitable connected members (not labeled) that are coupled to the actuator 230 (and here, that extend into the actuator 230). The support member 215 is fixedlyconnected to the moveable titled film guide 210 and the base 220. The support member 215 hold the movable titled film guide 210 at its fixed angled position. The support member 215 is moveable by the actuator 230 from a retracted position (shown in Figures 3A, 4A, 5A, 6A, and 7A) to an extended position (shown in Figures 3B, 4B, 5B, 6B, and 7B). When the support member 215 is in the retracted position, it causes the movable tilted film guide 210 to be spaced from the film F as shown in Figures 5 A, 6A, and 7A. When the support member 215 is in the extended position, it causes the movable tilted film guide 210 to engage the film F as shown in Figures 5B, 6B, and 7B. In this example embodiment, the moveable tilted film guide 210 is fixedly connected to the support member 215.

[0028] The base 220 is connected to the support member 215 such that the base 210 is movable with the support member 215 relative to the carriage frame 105. The base 220 is positioned slightly below the movable tilted film guide 210. The base 220 is movable by the support member 215 and the actuator 230 from a retracted position (shown in Figures 3A, 4A, 5A, 6A, and 7A) to an extended position (shown in Figures 3B, 4B, 5B, 6B, and 7B). In other embodiments, the base can be separate from the support member 215. In various such other embodiments, the base can be movable or stationary.

[0029] The actuator 230 is mounted on the bottom support (not labeled) of the frame 105 of the carriage 100 and is stationary in this example embodiment. The actuator 230 is controlled by the controller 60 and configured to move the support member 215 (as well as the guide 210 and base 220 connected to the support member 215) from their respective retracted positions to their respective extended positions. The actuator 230 is controlled by the controller 60. The actuator can vary in accordance with the present disclosure.

[0030] When the movable tilted film guide 210 is in its extended position, it is configured to direct the film F in a manner that shortens the width of the film F and specifically to cause a bottom part of the film to be manipulated into a rope form as best shown in Figures 6B and 7B. In the extended position, the movable tilted film guide 210 causes a bottom portion (such as 2-3 inches of the bottom portion) of the film F to fold upon itself to create the rope form at the bottom of the film F. Specifically, the movable tilted film guide 210 in the extended position causes a bottom outer edge of the film to move inward upon itself and toward the center of the film such that the film has shorter width and such that a lower part of the film is rolled upon itself to create a reinforced area of the film such as a rope form. The movable tilted filmguide 210 in the extended position can also cause the lower portion of the film that is manipulated into the rope form to be positioned below the load L and on the upper portion of the pallet P. More specifically, movable tilted film guide 210 creates a force on the film F that results in the film F sliding downwards relative to the tilted film guide 210 and that causes the bottom edge of the film F to be roped as the film F is rolling upon itself. The rope form is created in part by the bottom edge of the film F that moves downwardly engaging and being stopped by the base 220, so the rope form is formed against the base 220. In various embodiments, the base 220 can have a curved shape or a multi-curved shape to assist with this. The movable tilted film guide 210 is configured to engage the film F with relatively low friction to cause this sliding effect. If the friction is too high and there may be no sliding effect, and then only the top edge of the film F top may be manipulated. The movable tilted film guide 210 can additionally include a low friction non-stick coating to achieve this low friction functionality.

[0031] The operator interface 50 is configured to receive inputs from an operator and, in certain embodiments, to output information to the operator. The operator interface includes one or more input devices configured to receive inputs from the operator. In various embodiments, the one or more input devices include one or more buttons (such as hard or soft keys), one or more switches, and / or a touch panel. In various embodiments, the operator interface 50 includes a display device configured to display information to the operator, such as information about the palletized load, the status of the wrapping operation, or the parameters of the wrapping machine 1. The operator interface can include other output devices instead of or in addition to the display device, such as one or more speakers and / or one or more lights. In certain embodiments, the operator interface 50 is formed as part of the wrapping machine 1 and is, for instance, mounted to the wrapping-machine frame 10. In other embodiments, the operator interface is remote from the wrapping machine 1.

[0032] The controller 60 includes a processing device communicatively connected to a memory device. The processing device can include any suitable processing device such as, but not limited to, a general-purpose processor, a special-purpose processor, a digital-signal processor, one or more microprocessors, one or more microprocessors in association with a digital-signal processor core, one or more application-specific integrated circuits, one or more field-programmable gate array circuits, one or more integrated circuits, and / or a state machine. The memory device may include any suitable memory device such as, but not limited to, read-only memory, random-access memory, one or more digital registers, cache memory, one or more semiconductor memory devices, magnetic media such as integrated hard disks and / or removable memory, magneto-optical media, and / or optical media. The memory device stores instructions executable by the processing device to control operation of the wrapping machine 1 (such as to carry out a wrapping operation, as described below).

[0033] The controller 60 is communicatively connected to the actuators 30, 45, and 230 to control operation of these components in conjunction with the wrapping operations. The controller 60 is communicatively connected to the operator interface 50 to: (1) receive signals from the operator interface 50 that represent inputs received by the operator interface 50; and (2) send signals to the operator interface 50 to cause the operator interface 50 to output (such as to display) information.

[0034] A wrapping operation in which the wrapping machine 1 is used to wrap the load L and secure the load L to the pallet P is now described.

[0035] Initially, the circular guide 20 is at its upper position, the cutting-and-fixing device holds the leading end of the fdm F on the roll R, and the movable tilted fdm guide 210 of the roping assembly 200 is in the retracted position (as shown in Figures 3A, 4A, 5A, 6A, and 7A). The controller 60 controls the conveyor C to move the load L on the pallet P through the infeed area 10a and into the wrapping area of the wrapping machine 1.

[0036] After the load L on the pallet P reaches the wrapping area, the controller 60 controls the guide actuator 30 to lower the circular guide 20 such that the wrapping assembly 40 is at least partially vertically aligned with part of the load L. The controller 60 controls the cutting-and-fixing device to hold the leading end of the film F against the load L while controlling the wrapping-assembly actuator 45 to rotate the wrapping assembly 40 relative to the circular guide 20 and the load L. The rotation of the wrapping assembly 40 relative to the load L combined with the cutting-and-fixing device holding the leading end of the film F against the load L causes the film F to be drawn off of the roll R, directed through the components of the film carriage 100, and wrapped around the load L.

[0037] Once the film F has been wrapped around the leading end, the controller 60 controls the cutting-and-fixing device to release the leading end and move away from the load L. The controller 60 continues to control the wrapping-assembly actuator 45 to rotate the wrapping assembly 40 while controlling the guide actuator 30 to vertically move the circular guide 20 suchthat the load L is wrapped with the fdm F in a spiral pattern. During wrapping, the controller 60 also controls the feed rate of the film F and the pre-stretch the film F. Figures 6A and 7A illustrate this stage of the wrapping operation during which the film F is at its full width is wrapped around the load L.

[0038] Near the end of the wrapping operation (at least in this example embodiment), the controller 60 controls the wrapping machine 1 to apply the rope form to the load L and the pallet P. The controller 60 controls the actuator 230 to cause the actuator 230 to move the support member 215 to its extended position, which causes the movable titled film guide 210 to move to its extended position and the base 220 to move to its extended position. As the movable titled film guide 210 moves to its extended position, the movable tilted film guide 210 contacts and guides the film F at an angle and the base 220 contacts the bottom outer edge of the film F. The movable tilted film guide 210 and the base 220 thus manipulate the film F into the rope form and cause the bottom of the film to be engaged with the pallet P below the load L. This enables the wrapping machine 1 to use the film in a rope form to secure the load L to the pallet P (without having to raise the load L and the pallet P above the conveyor C).

[0039] Afterwards, the controller 60 controls the actuator 230 to move the support member 215 and the movable tilted film guide 210 and the base 220 attached thereto to their respective retracted positions which allows the film F to return to its full-width form. The controller 60 then controls the cutting-and-fixing device to cut the film F from the roll and secure the trailing end of the film F to the load L, thereby completing the wrapping operation. The controller 60 controls the conveyor C to move the wrapped load L and pallet P from the wrapping area and through the outfeed area 10b.

Claims

Claims1. A stretch-wrapping machine comprising: a frame that defines a wrapping area; and a wrapping assembly positioned at least partially within the wrapping area and comprising: a carriage, a movable tilted film guide supported by the carriage, and an actuator supported by the carriage and coupled to the movable titled film guide, the actuator configured to move the movable tilted film guide from a retracted position to an extended position, wherein in the extended position, the movable titled film guide is positioned to engage and cause a top edge of the film to move downwardly.

2. The stretch-wrapping machine of claim 1, wherein the movable titled film guide is angled downwardly from a top end thereof to a bottom end thereof.

3. The stretch-wrapping machine of claim 1, wherein the movable tilted film guide has an at least partially cylindrical film engaging surface.

4. The stretch-wrapping machine of claim 1, wherein in the retracted position, the movable tilted film guide is positioned to not contact the film.

5. The stretch-wrapping machine of claim 1, wherein the movable tilted film guide is at a fixed downwardly extending angle relative to the film.

6. The stretch-wrapping machine of claim 1, wherein the movable tilted film guide is not pivotable relative to the film.

7. The stretch-wrapping machine of claim 1, wherein the movable tilted film guide is at a fixed downwardly extending angle relative to a support member that supports the tilted film guide.

8. The stretch-wrapping machine of claim 1, wherein the movable tilted film guide is not pivotable relative to a support member that supports the tilted film guide.

9. The stretch-wrapping machine of claim 1, wherein the angle of the movable tilted film guide is fixed relative to the actuator.

10. The stretch-wrapping machine of claim 1, wherein the movable tilted film guide is not pivotable relative to the actuator.

11. The stretch-wrapping machine of claim 1, wherein the movable tilted film guide is movable from the retracted position to the extended position at a transverse angle to the film.

12. The stretch-wrapping machine of claim 1, wherein the movable tilted film guide is movable from the retracted position to the extended position at a perpendicular angle to the film.

13. The stretch-wrapping machine of claim 1, which comprises a support member connected to the actuator, wherein the movable titled film guide is fixedly connected to the support member, and wherein the actuator is configured to cause the support member to move the movable titled film guide from the retracted position to the extended position.

14. The stretch-wrapping machine of claim 13, which comprises a base connected to the support member, and the actuator is configured to cause the support member to move the base from a retracted position to an extended position simultaneously with moving the movable titled film guide from its retracted position to its extended position.

15. The stretch-wrapping machine of claim 14, wherein the base extends below the movable titled film guide.

16. The stretch-wrapping machine of claim 1, wherein in the extended position, the movable titled film guide is positioned to cause a bottom edge of the film into a rope form.

17. The stretch-wrapping machine of claim 1, wherein in the extended position, the movable titled film guide is positioned to cause a bottom edge of the film into a rope form configured to engage a pallet in the wrapping area below a top portion of the pallet.

18. A method of wrapping a load on a pallet, the method comprising: causing a titled film guide to be in a retracted position not engaging a film being wrapped around the load; and causing the tilted film guide to move to an extended position in engagement with the film being wrapped around the load to cause a top edge of the film to move downwardly.

19. The method of claim 18, wherein the movable tilted film guide is at a fixed downwardly extending angle relative to the film.

20. The method of claim 18, wherein the movable tilted film guide is not pivotable relative to the film.

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