U.S. patent application number 11/028977 was filed with the patent office on 2005-07-14 for modular shrink-wrap machine.
This patent application is currently assigned to Stork Fabricators, Inc.. Invention is credited to Gassel, Roger L., Stork, Brian R., Wilson, Tom.
Application Number | 20050150188 11/028977 |
Document ID | / |
Family ID | 22922401 |
Filed Date | 2005-07-14 |
United States Patent
Application |
20050150188 |
Kind Code |
A1 |
Stork, Brian R. ; et
al. |
July 14, 2005 |
Modular shrink-wrap machine
Abstract
Selectively reconfigurable shrink-wrap machine (30) for use with
a loading device (34) for individually wrapping products (58)
sequentially with shrink-wrap material (92) as delivered in
sequence to the machine. It includes a sensor (62) sensing product
position on the loading device. Shrink-wrap material is delivered
from a roll at a wrapping station (40). A first conveyor (42)
carries wrapped products between the wrapping station and a film
sealing and cutting apparatus (44). First conveyor delivers
products sequentially in synchronized velocity with the loading
device in response to sensor signals. Film sealing and cutting
apparatus has upper and lower heads (156, 164), at least one of
which is driven into and out of engagement with the other between
adjacent wrapped products received by the first conveyor for
effecting a sealed cut between them. Heads are each maintained at a
fixed angle of orientation. A second conveyor (43) receives wrapped
products sequentially from the sealing and cutting apparatus. A
microprocessor-driven touch screen (48) and a method controls the
shrink-wrap machine and is described.
Inventors: |
Stork, Brian R.;
(Washington, MO) ; Gassel, Roger L.; (Ellisville,
MO) ; Wilson, Tom; (Washington, MO) |
Correspondence
Address: |
GREENSFELDER HEMKER & GALE PC
SUITE 2000
10 SOUTH BROADWAY
ST LOUIS
MO
63102
|
Assignee: |
Stork Fabricators, Inc.
|
Family ID: |
22922401 |
Appl. No.: |
11/028977 |
Filed: |
January 4, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11028977 |
Jan 4, 2005 |
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10036029 |
Oct 29, 2001 |
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6854242 |
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60244360 |
Oct 30, 2000 |
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Current U.S.
Class: |
53/442 ;
53/450 |
Current CPC
Class: |
B65B 57/12 20130101;
B65B 59/00 20130101; B65B 59/001 20190501; B65B 53/02 20130101;
B65B 2210/04 20130101; B65B 65/00 20130101; B65B 9/067
20130101 |
Class at
Publication: |
053/442 ;
053/450 |
International
Class: |
B65B 053/02 |
Claims
1. (canceled)
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11. (canceled)
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20. (canceled)
21. A method for controlling a shrink-wrap machine having a sealing
head and vacuum conveyor axes, drive motors having drive axes, and
machine input/output ports, comprising: a) initializing variables;
b) setting scaling for the sealing head and the vacuum conveyor
axes; c) setting error checking bits; d) selectively locating a
film clamping zone and calculating a top dead center position for
the sealing head; e) controlling normal operations of all motor
axes; f) calculating ratios for web matching and cam following; g)
monitoring all machine input/output ports by continuously scanning
same; h) monitoring continuously all machine fault bits; i)
executing commands based on error bits; j) repeating steps a)-c)
and steps e)-i) upon user re-initialization of package size or
other modes as long as the machine is not turned off.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims priority of United
States Provisional Patent Application entitled Modular Shrink-Wrap
Machine, Ser. No. 60/244,360, filed 30 Oct. 2000.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The invention relates to apparatus for wrapping products
with heat shrinkable film and, more particularly, to a high-speed
modular shrink-wrap system for individually wrapping products
sequentially with shrink-wrap material.
[0004] Many arrangements have been known or proposed for wrapping
of products with heat-sealable or heat-shrinkable film material.
Co-assigned Stork U.S. Pat. No. 5,956,931 shows an apparatus for
wrapping products in which products are provided to a delivery
conveyor, wrapped in a tube of heat-sealable material, and to a
sealing station wherein sealing heads are brought into and out of
engagement with a tube to cut and seal the plastic, i.e. film
material forming the tube. The products, which are delivered as
wrapped packages onto an exit conveyor, proceed into a heat-shrink
station for final processing and discharge. That patent describes
an arrangement for positioning and movement of the sealing heads
which can be readily adjusted, as by operator input. Movement of
the head is detected by an electric eye which determines relative
dimensions of the product for initiating appropriate movement of
the sealing head or heads.
[0005] In addition, it has also been proposed to use computer
software programs for controlling the operation of such shrink-wrap
machines wherein the software can provide operator input to define
movement of sealing heads and other characteristics appropriate to
the type of seal, such fin seal, static seal, lap seal and other
types of seals, using machinery of this type.
[0006] It has also been proposed to use vacuum conveyors for
maintaining a package into tractive adherence, while wrapped in a
tube sealing material, while the product is brought into a sealing
position.
[0007] It has been proposed to use orbitally reciprocating sealing
heads or apparatus for sealing and severing each film-wrapped
package from each other, including with continuous motion of the
product on such a vacuum conveyor as it moves through the sealing
section and into an exit region and before heat-shrinking of the
film material about the wrapped product.
[0008] However, these prior art arrangements have not fully
achieved the speed and throughput or ease of adjustment and change
desired by customers. It has been found by the present inventors
that speed and throughput can be improved by more accurate sensing
of the position of products as they move from a delivery conveyor
into a heat sealing station, and by precisely controlling the
movement of sealing heads as they are brought into and out of
engagement with a tube of film material that wraps a product.
[0009] One of the challenges which face manufacturers of this type
of equipment is the need for the equipment to accommodate many
different types of products, widths, heights and shapes, as are
dictated by the uses to which the machines will be put. Heretofore,
prior art packaging systems and film-wrapping apparatus have not
provided to the full extent desired accommodation to these various
needs which will allow changes to be rapidly and effectively
carried out by an operator by simple control input, as compared
with time-consuming and difficult mechanical adjustments of
features. It is desirable to provide equipment of this scope with a
high degree of both mechanical and electrical changeability for
providing modular characteristics, by which both mechanical and
electrical features can be changed by the substitution of modules
or by software-implemented changes under the control of an
operator.
[0010] In apparatus of this type, installation may require the
operator to be positioned on either side of the machine relative to
the direction of movement of products through the machine. The
location of an operator may depend upon assembly line constraints.
For example, in replacement of existing equipment, a new machine
may require that the operator stand on one side which is the same
as in operating a previous machine. Further, in some installations,
a single operator may be desirably positioned between two product
wrapping lines so that, for example, product on one line will move
from right to left from the operator's perspective, but when the
operator faces in an opposite direction, will move from left to
right. Therefore, it is desirable that machines of this character
be ambidextrous in character, if possible, so as to allow an
operator to be located on either side of the machine.
SUMMARY OF THE INVENTION
[0011] Among the several objects, features and advantages of the
present invention may be noted the provision of automatic packaging
systems for wrapping products with film material, forming a
preselected type of package seal and for separating film material
wrapped about the product so as to provide individually wrapped
packages, which:
[0012] achieves extremely high speed and throughput;
[0013] during operation is capable of sensing precisely the
position of packages entering the machine;
[0014] when sensing the position of packages uses electronic,
microprocessor-controlled sensing of the position of products to
quickly and precisely bring cutting and sealing heads into and but
of engagement with products;
[0015] operates by wrapping, sealing and separating the wrapped
packages by using smooth, synchronized operation of sealing and
cutting heads in such a way as to avoid wasted, lost motion;
[0016] allows ready changeability of both mechanical and electronic
features by employing modular components;
[0017] allows quick operator reconfiguration in a facile manner
without costly set-up or time-consuming mechanical adjustments;
[0018] during change and adjustment allows software input to be
quickly and effectively made by display screen input;
[0019] allows processor-implemented changes to be carried out
electronically rather than mechanically;
[0020] is capable of ambidextrous use to permit an operator to be
located on either side of the collection of movement of packages
through the apparatus;
[0021] allows an operator input device to be reoriented to either
side of the machine; and
[0022] allows rapid changing or reloading of film material to
either side of the machine, being readily configurable for that
purpose.
[0023] Briefly, a selectively reconfigurable shrink-wrap machine
for use with a loading device for individually wrapping products
sequentially with shrink-wrap material. The loading device delivers
products in sequence to the machine for wrapping with shrink-wrap
material. Further, the shrink-wrap machine includes a sensor
associated with the loading device for sensing product position on
the loading device. Additionally, a film supply presents a roll of
shrink-wrap material that is associated with a wrapping station at
which products are wrapped with film material from the film
supply.
[0024] A first conveyor carries products wrapped in the film
material between the wrapping station and a film sealing and
cutting apparatus. Moreover, the first conveyor is driven to
deliver products sequentially in synchronized velocity with the
loading device in response to signals generated by the sensor.
[0025] The film sealing and cutting apparatus has an upper head and
a lower head. At least one the heads is driven for movement into
and out of engagement with the other head between adjacent film
wrapped products received by the first conveyor for effecting a
seal between adjacent products. Moreover, the upper head and the
lower head are each maintained at a fixed angle of orientation
relative to a direction of movement of products along the first
conveyor. A second conveyor is disposed adjacent the film sealing
and cutting apparatus for receiving wrapped products sequentially
from the sealing and cutting apparatus. As products are delivered
by the first conveyor, the film sealing and cutting apparatus
sequentially seals and cuts the products.
[0026] A microprocessor-driven control system has a touch sensitive
viewing and controlling means for prompting and receiving operator
response for controlling operation of the shrink-wrap machine. The
control system has microprocessor circuits selectively programmed
for control of at least one of a plurality of different possible
wrapping stations or modes of operation.
[0027] Other objects, features and advantages will be in part
apparent and in part pointed hereinbelow.
BRIEF DESCRIPTION OF DRAWINGS
[0028] FIG. 1 is a perspective view of apparatus for automatically
wrapping products in thermoplastic film, in accordance with and
embodying of the present invention.
[0029] FIG. 2 is a similar view with certain panels removed for
clarity.
[0030] FIG. 3 is a simplified plan view of the apparatus of FIG.
1.
[0031] FIG. 3A is an enlarged plan view of the loading conveyor of
FIG. 3.
[0032] FIG. 4 is a perspective view of heat sealing and cutting
apparatus and drive components used in the apparatus of FIG. 1.
[0033] FIG. 5 is a perspective view of a subassembly of FIG. 4.
[0034] FIG. 5A is a side view of a gear of FIG. 5.
[0035] FIG. 5B is a further side view of a gear of FIG. 5 of a gear
rotation of 180 degrees.
[0036] FIG. 6A is a simplified illustration of sealing and cutting
operations of the apparatus.
[0037] FIG. 6B is a further illustration of a sequence in the
cutting and sealing operations.
[0038] FIG. 6C is still further sequence in a sealing and cutting
operation.
[0039] FIG. 6D is a further illustration following a cutting
operation.
[0040] FIG. 7 is a perspective view of film supply apparatus of the
invention.
[0041] FIG. 8 is an exploded view of a film supply spindle and
spindle positioning components of the apparatus of FIG. 7.
[0042] FIG. 9 is a perspective view of a film quantity sensing
apparatus.
[0043] FIG. 10 is a block diagram of software modules of the
software of which operates the apparatus.
[0044] FIG. 11 is a perspective view of products along the vacuum
conveyor.
[0045] FIG. 11A is an end view illustrating a product wrapped in
film material having a static seal.
[0046] FIG. 11B is an end view illustrating a product wrapped in
film material having a fin seal.
[0047] FIG. 12 is a perspective view of apparatus with further
panels removed.
[0048] FIG. 13 is a perspective view of products interspersed with
missing products along the vacuum conveyor.
[0049] FIG. 14 is a simplified illustration of sealing and cutting
operations of the apparatus with missing products interspersed.
[0050] Corresponding reference characters identify corresponding
elements throughout the several views of the drawings.
DESCRIPTION OF PRACTICAL EMBODIMENTS
[0051] Referring to the drawings, the new shrink-wrap machine is
generally indicated at 30 in FIG. 1. Referring to FIGS. 1-3,
shrink-wrap machine 30 comprises a support frame 32 which supports
a loading conveyor 34. As further shown, a wrapping station 40 is
disposed adjacent support frame 32. Additionally, a film dispensing
station 36 is disposed adjacent wrapping station 40. A support
frame 38 secures a vacuum conveyor 42 which is disposed adjacent
film dispensing station 36. Support frame 38 secures exit conveyor
50 which is disposed a predetermined distance from vacuum conveyor
42 with a film sealing and cutting apparatus 44 interposed
therebetween. A guard frame 46 which encloses film sealing and
cutting apparatus 44, pivotally secures touch sensitive monitor
48.
[0052] As shown in FIGS. 1, 3 and 3A, loading conveyor 34 comprises
a support frame 32 for securing a slotted belt 54 which proceeds in
a longitudinal direction along loading conveyor 34 beneath loading
surface 35. A longitudinal slot 37 is formed in loading surface 35,
exposing belt 54. Further, opposing guides 52 which run
longitudinally along loading surface 35, may be selectively
separated to correspond to the width of products 58 proceeding
longitudinally along loading conveyor 34. To maintain a
predetermined spacing between adjacent products 58, multiple
equidistantly spaced product propelling means 56, preferably lugs,
are inserted in slotted belt 54. Slotted belt 54 is driven by a
motorized means 60, preferably a permanent magnet D.C. motor. A
sensor 62 (not shown but represented by dashed line in FIG. 1) is
disposed along belt 54 for sensing the position of lugs 56 as lugs
56 travel past sensor 62. As can be appreciated by one skilled in
the art, sensor 62 generates electrical signals in accordance with
the Hall Effect. Using these generated electric signals permits
shrink-wrap machine 30 to synchronize belt speeds and effect
precise control of product 58 position during operation.
[0053] Referring to FIGS. 1 and 7, film dispensing station 36 is
explained. Film dispensing station 36 is comprised of a pair of
vertical support members 64 which are securely connected to support
frame 38 by brackets 66. Further, a proximally positioned vertical
support member 64 is securely connected to an open support end 68
having a pair of pivoting members 67 which are prevented from
pivoting by pins 69. A distally positioned vertical support member
64 is securely connected to a closed support end 70. A spindle
member 72 is disposed between open support end 68 and closed
support end 70 for carrying a roll of film material 92 thereon.
Access for removal of a roll of film material is effected by
actuating pin 69 whereby member 67 pivots to position 71. As is
shown in FIG. 7, film dispensing station 36 may accommodate two
separate rolls of film material 92.
[0054] Referring to FIGS. 7 and 8, spindle member 72 is further
disclosed. Spindle member 72 comprises a central shaft 94 which
further includes a distal end 95 and a proximal end 96. Distal end
95 is nonrotatably attached to closed support end 70. An outer
shaft 97 which further includes an inside surface 99 and an outside
surface 103 slides over central shaft 94 and is maintained in
concentric rotational proximity along longitudinal axis 101 by
multiple bearings 98. A pair of locking collars 100 are slidably
fitted upon opposing ends of outer shaft 97 for securing a roll of
film material 92 therebetween. As is further shown, central shaft
94 includes a threaded portion 102 along its proximal end 96.
Adjustment collar 104 includes a proximal segment 107 having a
knurled gripping surface 105 and a distal segment 109 having an
outside surface 111. Adjustment collar 104 further includes a
knurled gripping surface 105 for ready operator adjustment.
Additionally, a ring 108 having an inside surface 110 and an
outside surface 113 is fitted upon outside surface 111 establishing
a press fit therebetween.
[0055] Although shown in FIG. 8 in an exploded view, outside
surface 113 of ring 108 of adjustment collar 104 is assembled into
inside surface 99 of outer shaft 97. Therefore, adjustment collar
104, ring 108 and outer shaft 97 are of integral construction.
Thus, one of ordinary skill in the art can appreciate that as
adjustment collar 104 is rotated about longitudinal axis 101 after
being placed in threaded engagement with central shaft 94, as
adjustment collar 104 proceeds in either direction along
longitudinal axis 101, outer shaft 97 likewise proceeds along
longitudinal axis 101 due to the integral construction between
adjustment collar 104 and outer shaft 97. Moreover, locking nut 112
has a knurled gripping surface 116 and an internally threaded
aperture 114 that may be placed in threaded engagement with
threaded portion 102. By grasping knurled gripping surface 116 and
rotating locking nut 112 along longitudinal axis 101 in a direction
toward adjustment collar 104 until there is secure contact
therebetween, locking nut 112 will prevent adjustment collar 104
from rotating with respect to central shaft 94. It is appreciated
that this arrangement permits an operator to move a film roll 92 in
either direction along longitudinal axis 101 by rotating adjustment
collar 104 which is in threaded engagement with central shaft 94 in
a desired direction along longitudinal axis 101 while the
shrink-wrap machine 30 of the present invention is in
operation.
[0056] Referring to FIG. 7, retarding device 74 is shown. Retarding
device 74 includes an elongated member 76 having a proximal end 78
and recessed region 80 immediately adjacent proximal end 78.
Further, distal end 82 is securely connected in closed support end
70. Retarding device 74 is configured to receive a flexible
retarding member 84. Flexible retarding member 84 includes a first
loop 86 which is pivotally engaged with recessed region 80 of
elongated member 76 and a second loop 88 that secures a weight 90
for maintaining retarding member 84 in position. As shown, flexible
retarding member 84 extends over and around the periphery of a roll
of film material 92, providing non-marring frictional resistance to
rotation of a roll of film material 92 about longitudinal axis 83,
89 while dispensing film material 92 about products 58. The
frictional resistance that is generated between inner surface 85
and the periphery of a roll of film material 92 is not specifically
shown, as film material 92 is depicted in phantom lines for
purposes of clarity. It is appreciated that this frictional force
will tend to minimize the amount of unrestricted dispensing of film
material 92 when wrapping operation is halted.
[0057] Referring to FIG. 9, indexing device 118 is further
illustrated. Index device 118 includes an elongated portion 120
having a proximal end 122 and a distal end 124. As is shown,
elongated portion 120 protrudes through closed support end 70 so
that elongated portion 120 may rotate about its longitudinal axis
126. Further, a first sensing member 128 extends radially from
proximal end 122, and second sensing member 130 extends radially
from distal end 124. First sensing member 128 and second sensing
member 130 are situated in a predetermined angular relationship
with each other and with respect to longitudinal axis 126. As is
further shown, a first curved slot 132 and a second curved slot 134
is formed in closed support end 70. Additionally, a first sensing
device 136 and a second sensing device 138 are disposed in first
curved slot 132 and second curved slot 134, respectively for
sensing a predetermined extent of depletion and total depletion,
respectively, of a roll of film material 92. It is further
appreciated that a second set or pair of curved slots and sensing
devices are provided as film dispensing station 36 is configured to
secure two rolls of film material 92. Sensing devices 136, 138
operate in accordance with the Hall Effect and send electrical
signals when second sensing member 130 passes in sufficiently
proximately therewith. Additionally, an operator warning device
(not shown) may be provided for warning an operator of a
predetermined extent of depletion or total depletion, respectively,
of a roll of film material 92.
[0058] Referring to FIG. 9, first sensing member 128 rests atop
outer surface 87 of flexible retarding member 84 for monitoring the
amount of shrink-wrap material 92 remaining on a roll. Second
sensing member 130 is pivotally adjacent first and second sensing
devices 136, 138. As the roll of shrink-wrap material 92 is
expended, first sensing member 128 maintains an offset tangential
contact along the radius of the roll. This offset is due to the
thickness of the flexible retarding member 84 as first sensing
member 128 rotates about longitudinal axis 126 of the elongated
portion 120. Likewise, second sensing member 130 rotates about
longitudinal axis 128. As the film roll of shrink-wrap material 92
is expended to a predetermined level, second sensing member 130
achieves such proximity with first sensing device 128 as to
activate first sensing device 136 and thereby alert an operator of
a predetermined level of depletion of film material 92 from a film
roll. Upon the roll being totally expended of film material 92,
second sensing member 130 achieves such proximity with second
sensing device 138 as to activate second sensing device 138 thereby
alerting the operator that film material 92 of a film roll has been
totally expended.
[0059] Referring to FIGS. 1 and 3, wrapping station 40 is disposed
adjacent loading conveyor 34 for receiving products propelled by
lug 56. Wrapping station 40 is well known in the art, using film
material 92 for wrapping product 58 by directing film material 92
from film dispensing station 36 to closely wrap products 58
peripherally along their longitudinal axes within a continuous tube
93 of film material 92 so that tube 93 is formed therearound
product 58 (FIG. 11). Referring to FIGS. 11A, an overlapping region
81 is formed between opposed ends 79 of film material 92. A sealing
device 41 (FIG. 1) disposed adjacent wrapping station 40
establishes a continuous seam 77 along overlapping region 81.
Referring to FIG. 1, wrapping station 40 establishes a static seal.
Although different types of wrapping stations are used to form
different kinds of seals (FIGS. 11A, 11B), which are also known in
the art, shrink-wrap machine 30 of the present invention provides
for modular wrapping stations 40 which may be selectively installed
according to a customer's preference.
[0060] Referring to FIGS. 1 and 6A, vacuum conveyor 42 is disposed
adjacent film dispensing station 36 and carries film tube 93 which
is very closely wrapped around product 58. Further, by generating a
partial pressure along vacuum conveyor 42, products 58 are
sequentially conveyed without their being shifted from the position
at which product 58 first makes contact with vacuum conveyor 42.
Moreover, movement along vacuum conveyor 42 is maintained in
synchronization with loading conveyor 34 because the motorized
means, preferably a stepper motor, driving vacuum conveyor 42
receives electrical signals generated by sensor 62, which is most
preferably a Hall Effect sensor, and which produces a voltage each
time a lug 56 passes sensor 62 (not shown). This arrangement
permits uniform spacing 150 between adjacent products 58 travelling
along the longitudinal axis of vacuum conveyor 42.
[0061] Referring to FIGS. 2, 4, 5, and 6A-6D, film sealing and
cutting apparatus 44 is disposed at a predetermined fixed distance
from vacuum conveyor 42. Additionally, apparatus 44 is configured
to move into and out of engagement between adjacent film wrapped
products 58. In making these movements, apparatus 44 places a
transverse cut 91 or end seal between adjacent sequentially
presented products 58 before passing newly separated products 58,
or packages 59 (FIGS. 6A, 6D), onto exit conveyor 43.
[0062] Referring to FIGS. 4 and 5, upper gear 142 is rotatably
connected to frame structure 140 about center axis 144. As is
shown, fixed central gear 146 is non-rotatably secured along center
axis 144. First eccentric gear 148 which is carried by uppergear
142 meshes with central gear 146 that further meshes with second
eccentric gear 150 which is also carried by upper gear 142. As is
further shown, second eccentric gear 150 rotates about eccentric
axis 152.
[0063] Therefore, as upper gear 142 rotates about center axis 144,
first eccentric gear 148 is urged into rotation by meshing
engagement with central gear 146. Additionally, second eccentric
gear 150 which rotates about eccentric axis 152 is placed in
opposing rotation with respect to upper gear 142. Thus, second
eccentric gear 150, although eccentrically rotating about center
axis 144, rotates about eccentric axis 152 so that lower gear 162
is maintained in alignment with vertical axis 200. As is shown in
FIGS. 5A and 6A-6D, rotation of second eccentric gear 150 about
eccentric axis 152 is best explained by use of reference point 153.
Reference point 153 in FIG. 5A appears on the upper periphery of
second eccentric gear 150 in-line with vertical axis 200. Referring
to FIG. 5B, reference point 153 continues to appear at the top
vertical position of second eccentric gear 150 in-line with
vertical axis 200. Therefore, as shown on FIGS. 5A and 5B and
6A-6B, while lower gear 162 completes a rotation cycle about center
axis 170, second eccentric gear 150 rotates about eccentric axis
172 so that upper head 156 remains parallel to vertical axis
200.
[0064] Referring to FIGS. 4 and 5, upper head 156 includes a body
154 having a pair of in-line apertures 155 on opposing ends of body
154. Apertures 155 accept opposing shafts 157 which extend from
second eccentric gears 150 for rotational orientation with respect
to eccentric axis 152. Upper head 156 further includes a cutter
portion 158 disposed between a pair of film clamps 160. Cutter
portion 158 and film clamps 160 are slidably movable along pins
161. Further, multiple hat-shaped structures 163 are biased against
multiple springs 159 to force both cutter portion 158 and film
clamps 160 in an extended position.
[0065] Referring to FIG. 5, lower gear 162 includes a fixed central
gear 146 which is non-rotatably mounted to frame structure 140,
although lower gear 162 may rotate about center axis 170. As is
shown, first eccentric gear 148 meshes with central gear 146 and
second eccentric gear 150 likewise meshes with first eccentric gear
148. Second eccentric gear 150 rotates about eccentric axis 172.
Therefore, as lower gear 162 rotates about center axis 170, first
eccentric gear 148 is urged into rotation by meshing engagement
with central gear 146. Additionally, second eccentric gear 150
which rotates about eccentric axis 172 is placed in opposing
rotation with respect to lower gear 162. Thus, second eccentric
gear 150, although eccentrically rotating about center axis 170,
rotates about eccentric axis 172 so that lower gear 162 is
maintained in alignment with vertical axis 200. As is shown in
FIGS. 5A and 6A-6D, rotation of second eccentric gear 150 about
eccentric axis 152 is best explained by use of reference point 153.
Reference point 153 in FIG. 5A appears on the upper periphery of
second eccentric gear 150 in-line with vertical axis 200. Referring
to FIG. 5B, reference point 153 continues to appear at the top
vertical position of second eccentric gear 150 in-line with
vertical axis 200. Therefore, as shown on FIGS. 5A and 5B and
6A-6B, while upper gear 142 completes a rotation cycle about center
axis 144, second eccentric gear 150 rotates about eccentric axis
152 so that upper head 156 remains parallel to vertical axis
200.
[0066] As is shown in FIGS. 4 and 5, lower head 164 includes a body
174 having a pair of in-line apertures 176 on opposing ends of body
174. Apertures 176 accept opposing shafts 151 which extend from
second eccentric gears 150 for rotational orientation with respect
to eccentric axis 172. Body 174 further includes multiple apertures
178 for accepting in sliding contact therein pins 180 which
protrude from platen portion 182. Springs 184 are fitted upon pins
180 prior to insertion into body 174 and bias body 174 in a
direction away from platen head portion 182, that is, in a
direction along the longitudinal axes of pins 180.
[0067] Referring to FIGS. 4 and 5, the interrelationship between
upper gear 142 and lower gear 162 is now explained. A pair of
serpentine belts 186 mesh about the peripheries of upper gear 142
and lower gear 162. Each serpentine belt 186 meshes an outer pulley
188 secured in non-rotating orientation with respect to a shaft
192, with an inner pulley 190 being disposed between outer pulleys
188 along shaft 192. Shaft 192 is journaled to frame structure 140.
As is further shown, a belt 194 engages inner pulley 190 and pulley
196 of motorized means 198, preferably a servo motor. One skilled
in the art can appreciate that upper gear 142 and lower gear 162
are being driven in opposing rotational directions about their
respective center axes 144, 170. As further appreciated that upper
head 156 is carried having a fixed angle of orientation, preferably
with vertical axis 200, and that lower head 164 is likewise carried
having a fixed angle of orientation, preferably in alignment with
vertical axis 200. Referring to FIGS. 6A-6D, it is appreciated that
upper head 156 and lower head 164 are maintained synchronously and
mutually toward and away from each other about a predetermined
path. Thus, cutter portion 158 of upper head 156 and platen head
portion 182 of lower head 164 are engaged once for every full
rotation of upper gear 142 and lower gear 162. Additionally, due to
the rotation of upper head 156 with respect to eccentric axis 152
and lower head 164 with respect to eccentric axis 172, it is
appreciated that upper head 156 and the lower head 164 rotate in
and out of engagement while maintaining a fixed angle of
orientation, preferably in-line with a vertical axis 200. Further,
it is appreciated that cutter portion 158 and the platen head
portion 182 each maintain a predetermined path, preferably
circular, due to the epicyclical arrangement with gears 146, 148
and 150.
[0068] Referring to FIG. 12, the vertical adjustment of film
sealing and cutting apparatus 44 now disclosed. It is appreciated,
that for symmetry, apparatus 44 most efficiently performs its task
by engaging film material along a product's mid-point axis 202
(FIG. 6A). Thus, a means to vertically adjust the entire apparatus
44 is required. This is effected, by use of a motorized means 218,
such as a permanent D.C. motor. Motorized means 218 is secured to
support frame 38 for driving a chain belt 220 which engages a gear
222. Gear 222 is secured to a proximal end 226 of a shaft 224 with
a mounting means 228 securing to a distal end 229 of shaft 224.
Further, bevel gears 230 are disposed along shaft 224 and at
proximal ends 232 of threaded shafts 234. Shafts 234 are threadedly
engaged with blocks 236 of apparatus 44. Thus, motorized means 218
drives gear 222, which imparts rotation to shaft 222 that further
rotates bevel gears 230 disposed along shaft 224. Further, bevel
gears 230 at proximal ends 232 of threaded shafts 234, being meshed
with bevel gears 230 along shaft 224, impart rotation about
threaded shafts 234. By rotating threaded shafts 234 with respect
to blocks 236, apparatus 44 is raised or lowered until the desired
height is reached.
[0069] Referring to FIGS. 1 and 6A, exit conveyor 50 is disposed in
close proximity with apparatus 44 and vacuum conveyor 42. Exit
conveyor 50 receives sequentially delivered products 58 from vacuum
conveyor 42 and apparatus 44 after a transverse seal 91 has been
placed between each adjacent product 58. A motorized means 236
(FIG. 12), preferably a permanent magnet D.C. motor, is utilized to
carry products 58 sequentially therefrom in a predetermined
relationship with respect to loading conveyor 34. As will be
explained in greater detail below, the operator may find it
desirable to drive exit conveyor 50 at a lower speed than vacuum
conveyor 42 is driven.
[0070] Referring to FIGS. 1, 3 and 7, a novel, user-friendly
feature of shrink-wrap machine 30 is disclosed. A touch sensitive
monitor 48 includes an arm 49 which is pivotally engaged with guard
frame 46. Further, film dispensing station 36 includes an open
support end 68 from which an operator 47 may either load or unload
a roll of film material 92. An operator 47 may grasp monitor 48 and
pull monitor 48 towards the operator so that arm 49 pivots about
guard frame 46, thus moving monitor 48 on the same side of machine
30 as open support 68 of film dispensing station 36. Additionally,
operator 47 may rotate monitor 48 about its base 51 if desired. By
having both monitor 48 and open support 68 on the same side of
machine 30, maintenance and normal operations are greatly
simplified. Moreover, because monitor 48 can be pivoted to either
side, and due to interchangeability between support 68 and support
70 of film dispensing station 36, machine 30 is ambidextrous. That
is, operator 47 may choose a desired side of operations of machine
30.
[0071] Referring to FIG. 10, flow diagram 250 is now explained.
Flow diagram 250 includes the following modules which are contained
in a box and includes set-up program 252, which after a reference
button is pushed (Step 253), proceeds into homing program 254 that
thereafter proceeds into either main program 256 or to PLC program
258. A fault program 260 continuously runs in the background but is
not specifically part of the flow diagram. These
microprocessor-driven programs define a control system for the
machine.
[0072] Set-up program 252 includes initializing variables for
operation of the machine and include provision for the operator
to:
[0073] specify the height, width and length of a package
[0074] indicate type of seal desired
[0075] set the speed of the loading conveyor
[0076] set the speed of exit conveyor
[0077] set the temperature of cutting head.
[0078] Additionally, set-up program 252 sets the scaling for the
servo axis which includes a predetermined number of counts per
degree rotation of sealing and cutting apparatus 44, and vacuum
conveyor 42 which additionally has a predetermined number of counts
per unit displacement along the longitudinal direction of vacuum
conveyor 42. This scaling permits shrink-wrap machine 30 to
extremely accurately calculate the position of products 58 as they
proceed down vacuum conveyor 42 and reach apparatus 44.
Additionally, set-up program 252 sets error checking bits, the
violation of which may terminate operation of shrink-wrap machine
30.
[0079] Homing program 254 must be initially invoked by depressing
reference button 253. Once reference button 253 is depressed,
homing program 254 finds the film clamping zone 262 (FIGS. 6B, 6C).
Film clamping zone 262 refers to the angular range in which upper
head 156 and lower head 164 are in contact with film material 92
between adjacent products. Additionally, homing program 254
calculates the top dead center position (not shown), wherein upper
head 156 is located at its uppermost position in its movement cycle
and lower head 164 is positioned at its lowest vertical position
with respect to its cycle of movement. Therefore, the top bid
center position corresponds to the tallest product that the
shrink-wrap machine can accommodate. Moreover, homing program 254
also references the ceiling height to which motorized means 218
must move apparatus 44 so that upper head 156 and lower head 164
are engaged at a height that corresponds to one-half of the height
of an incoming product down the vacuum conveyor 42. Main program
256 controls the normal operation of all motor positions or axes.
In addition, main program 256 calculates the ratios between web
matching and cam following. Web matching refers to matching the
speed of product 58 along vacuum conveyor 42 with the horizontal
speed of apparatus 44 while upper head 156 and lower head 164 are
in the film clamping zone. Cam following refers to the 360 degree
rotational speed motion of upper head 156 and lower head 164.
[0080] PLC program 258 monitors all machine input and output
stations while continuously scanning. Reference button 253 is
pushed only when initially turning on the machine and is not again
required to be pressed until after a machine is shut off, it is
only during the initial turn-on period.
[0081] Full program 260 monitors all machine fault bits
continuously as it is a program that runs in the background. Fault
program 262 monitors commands based on error bit detection, taking
predetermined steps to address any particular error. Some error
bits can be operator configured such as electing or not electing to
activate an alarm when a film roll is expended.
[0082] Set-up program 252 permits an operator great flexibility and
ease of operation by permitting the operator to input dimensions
for different packages to be processed without the operator having
to otherwise physically make any other alterations to the
shrink-wrap machine.
[0083] Referring to FIGS. 1, 2, 3, 3A, 6A-6D, 11, and 11A-11B, the
operation of machine 30 shall be discussed. After operator 47 has
turned on the machine 30 and has made selections on touch sensitive
monitor 48, machine 30 indicates on monitor 48 the proper spacing
for lugs 56 along loading conveyor 34. Additionally, the correct
wrapping station 40 must be installed into machine 30. Further, at
least one roll of film material 92 must be loaded onto film
dispensing station 36 and threaded through wrapping station 40
before the wrapping process for products 58 may commence. Products
58 are placed on loading conveyor 34 and properly spaced as shown
in FIG. 3A and sequentially propelled into wrapping station 40 by
lugs 56. Products 58 then begin to pass in sequential procession
through wrapping station 40, wherein each product is closely
wrapped peripherally about its longitudinal axis within a
continuous tube of film material 93 formed therearound. Opposing
ends of shrink-wrap material 92 wrap products 58, forming regions
of overlapping shrink-wrap material 81 along the products'
longitudinal axes. A sealing device in association with the modular
wrapping station 40 (not shown) establishes a continuous seam 77
along the region of overlapping shrink-wrap material 81. It can be
appreciated by one skilled in the art that wrapping station 40 may
be of multiple configurations. Therefore, the region of overlapping
material 81 may be differently configured as would be the sealing
arrangement required to establish the seam 77 between overlapping
material 81.
[0084] Referring to FIG. 6A, products 58 proceeding along vacuum
conveyor 42 are snugly wrapped in a tube 93, and move with the film
wrap material at a first predetermined spacing 204 therebetween.
Products 58 further proceed along vacuum conveyor 42 toward film
sealing and cutting apparatus 44 for receiving a transverse seal 91
between each adjacently positioned product 58.
[0085] Referring to FIGS. 6A-6D, the process for introducing
transverse cuts 91 between adjacent products 58 is now discussed.
For clarity, an additional distinction between products is shown by
reference characters character A, B, C or D within the product box.
Thus, referring to FIG. 6A, package A has already passed film
sealing and cutting apparatus 44, is on exit conveyor 43 and ready
for delivery into heat chamber (not shown). The term "package" is
applied to wrapped products that have received transverse seals of
film material in front of its leading end and after its trailing
end. Product B has received a transverse seal 91 in front of its
leading end 208 with cutter portion 158 and platen head portion 182
rotating in position to place a transverse seal 91 between trailing
end 210 of product B and leading end 212 of product C. Further, as
shown on FIG. 6A, the spacing between adjacent products such as
between product C and product D which initially is first
predetermined spacing 204, may be revised or reduced such as
between product B and C to a second predetermined spacing 206. This
reduced spacing may be desirable for a taller product 58.
Therefore, assuming the product 58 to be tall, to effect the
shorter second predetermined spacing 206, exit conveyor 43 must
operate at a slightly slower speed than that of vacuum conveyor 42.
Thus, as leading end 208 of product B comes into contact with exit
conveyor 43, the speed of product B becomes slightly less with
respect to product C which is still on vacuum conveyor 42, thereby
producing second predetermined spacing 206 between product B and
product C. This reduced spacing produces a condition of reduced
tension of film tube 93 which permit cutter portion 158 and platen
head portion 182 to effect an improved transverse seal 91 between
product B and product C.
[0086] Referring to FIG. 6B, cutting portion 158 and platen head
portion 182 first come into contact with film tube 93. This range
of contact between cutter portion 158 and platen head portion 182
is referred to as the film clamping zone 262 which extends 20
degrees to either side of the vertical axis 200. It may be
appreciated that maintaining upper head 156 and lower head 164 and
fixed relationship therebetween, preferably along vertical axis
200, permits an improved seal due to equal tension of film tube 93
between product B and product C. As is shown on FIG. 6C, cutting
head 158 and platen portion 182 remain in contact with each other,
and have effected a transverse seal 91 between product B and
product C. Further, FIG. 6D shows cutter portion 158 and platen
head portion 182 movement out of contact from between product B and
product C, transverse seal 91 having been formed therebetween. As
is appreciated, this process for establishing transverse seal 91 is
sequentially repeated for product C, B and so on.
[0087] Moreover, an additional operational aspect of the machine 30
is discussed. As earlier noted, sensor 62 (not shown) senses a
product propelling means 56, preferably lugs, not the product 58
itself. Thus, sensor 62 generates signals corresponding to an
anticipated product 58 position, irrespective of the existence of a
product 58 in that position. Referring to FIGS. 13 and 14, this
"missing product" condition is illustrated. For clarity, an
additional distinction between products is shown by reference
characters character A, B, C or D within the product box or if
there is no product, i.e., a missing product, the character is
circled. As is illustrated in FIG. 13 wrapped in continuous film
material tube 93, products B and D appear interposed with missing
products A and C.
[0088] Referring to FIG. 14, it is shown that missing product A and
product B have been separated by transverse seal 91 and missing
product C has received a first transverse seal 91. Therefore,
without operator intervention, and so long as sufficient film
material 92 remains on film dispensing station 36, machine 30
operates normally. That is, film sealing and cutting apparatus 44
will continue to form transverse seals 91 in film tube 93 between
anticipated positions of adjacent products 58.
[0089] In addition, a method for controlling a shrink-wrap machine
comprises:
[0090] a) initializing variables;
[0091] b) setting scaling for the sealing head and the vacuum
conveyor axes;
[0092] c) setting error checking bits;
[0093] d) selectively locating a film clamping zone and calculating
a top dead center position for the sealing head;
[0094] e) controlling normal operations of all motor axes;
[0095] f) calculating ratios for web matching and cam
following;
[0096] g) monitoring all machine input/output ports by continuously
scanning same;
[0097] h) monitoring continuously all machine fault bits;
[0098] i) executing commands based on error bits;
[0099] j) repeating steps a)-c) and steps e)-i) upon user
re-initialization of package size or other modes as long as machine
is not turned off.
[0100] In view of the foregoing description of the present
invention and various embodiments and methods it will be seen that
the several objects of the invention are achieved and other
advantages are attained.
[0101] The embodiments were chosen and described in order to best
explain the principles of the invention and its practical
application to thereby enable others skilled in the art to best
utilize the invention in various embodiments and with various
modifications as are suited to the particular use contemplated.
[0102] As various modifications could be made in the constructions
and methods herein described and illustrated without departing from
the scope of the invention, it is intended that all matter
contained in the foregoing description or shown in the accompanying
drawings shall be interpreted as illustrative rather than
limiting.
* * * * *