U.S. patent application number 11/443559 was filed with the patent office on 2006-11-16 for apparatus and method for binding a load with tape.
Invention is credited to Bruce Naylor Cox, David Wakefield.
Application Number | 20060254214 11/443559 |
Document ID | / |
Family ID | 3824695 |
Filed Date | 2006-11-16 |
United States Patent
Application |
20060254214 |
Kind Code |
A1 |
Cox; Bruce Naylor ; et
al. |
November 16, 2006 |
Apparatus and method for binding a load with tape
Abstract
An apparatus for binding a three-dimensional load with tape
comprises a turntable for rotating the load, a tape dispenser and a
logistical controller. The tape dispenser is moveable relative to
the turntable and the load. The detector detects the top of the
load, and is moveable with the tape dispenser. The logistical
controller is arranged to control rotation of the load and movement
of the tape dispenser. In particular, the controller is arranged to
operate the apparatus to dispense the tape according to a
predetermined default pattern until the detector determines the top
of the load. Once the tope of load is detected, the controller is
arranged to operate the apparatus according to a corrected pattern
based upon the detected top of load. Further, the controller may
comprise a computer program which calculates the required turntable
speed for a substantially constant predetermined speed of the
carriage such that the relative position of the turntable and the
carriage is such that the load is bound according to the default
pattern or the corrected pattern.
Inventors: |
Cox; Bruce Naylor; (Yinnar
South, AU) ; Wakefield; David; (Moe, AU) |
Correspondence
Address: |
ANDRUS, SCEALES, STARKE & SAWALL, LLP
100 EAST WISCONSIN AVENUE, SUITE 1100
MILWAUKEE
WI
53202
US
|
Family ID: |
3824695 |
Appl. No.: |
11/443559 |
Filed: |
May 31, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10398675 |
Jul 15, 2003 |
7114308 |
|
|
PCT/AU01/01263 |
Oct 9, 2001 |
|
|
|
11443559 |
May 31, 2006 |
|
|
|
Current U.S.
Class: |
53/399 ; 53/587;
53/64 |
Current CPC
Class: |
B65B 11/045
20130101 |
Class at
Publication: |
053/399 ;
053/064; 053/587 |
International
Class: |
B65B 57/02 20060101
B65B057/02; B65B 11/56 20060101 B65B011/56 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 9, 2000 |
AU |
PR 0637 |
Claims
1. An apparatus for binding a three-dimensional load with tape, the
apparatus comprising: a turntable for supporting and rotating the
three-dimensional load; a tape dispenser for dispensing tape, the
dispenser being moveable relative to the turntable and the load; a
logistical controller arranged to control rotation of the load and
movement of the tape dispenser; and a detector to detect the top of
the load, the detector being moveable with the tape dispenser,
wherein the controller is arranged to operate the apparatus to
dispense the tape according to a predetermined default pattern
until the detector determines the top of the load, whereafter, the
controller is responsive to a signal from the detector
corresponding to the detected top of load to operate the apparatus
according to a corrected pattern based upon the detected top of
load.
2. The apparatus as defined in claim 1 wherein the tape dispenser
is provided on a moveable carriage driven up and down a mast, and
the detector is mounted on the carriage.
3. The apparatus as defined in claim 2 wherein the detector is
spaced above the tape dispenser to provide advance warning to the
controller in an upward path of the tape dispenser that the tape is
approaching the top of the load.
4. The apparatus as defined in claim 1 wherein the corrected
pattern applied to the load is a helical pattern comprising a
plurality of upward and downward helixes which are spaced from each
other with at least some of the upward helixes crossing at least
some of the downward helixes, the upward and downward helixes
extending between upper and lower limits and wherein the default
pattern comprises an upward helix and the controller operates the
apparatus to dispense the tape in the upward helix of the default
pattern according to a default pitch.
5. The apparatus as defined in claim 4 wherein the tape is applied
at a default pitch until the detector detects the top of the load,
whereafter the controller calculates a corrected pitch and operates
the apparatus to apply the remaining upward and downward helixes at
the corrected pitch.
6. The apparatus as defined in claim 5 wherein the corrected pitch
is calculated so that the tape will be applied to a whole number of
sides of the load as it traverses between the upper and lower limit
and vice versa.
7. The apparatus as defined in claim 1 wherein the controller
controls the apparatus to commence at an intermediate height of the
load.
8. The apparatus as defined in claim 4 wherein the controller is
arranged to receive a number of user inputs through the use of a
keypad or other data entry means including values corresponding to
the upper and lower limits of the pattern array, the pattern array
being the vertical extent of the applied default and corrected
helical patterns.
9. The apparatus as defined in claim 8 wherein the controller is
arranged to calculate the array height from an input from the
detector and the values corresponding to the upper and lower limits
of the pattern array and wherein the controller determines the
corrected pattern based on the array height.
10. The apparatus as defined in claim 4 wherein the controller
determines an adjustment which is required in the default pattern
so that the tape reaches the upper limit coinciding with the end of
an inclined pass of tape across a side of the load.
11. A method of binding a three-dimensional load with tape, the
method comprising: a) binding the load with tape dispensed from a
movable tape dispenser according to a default pattern; b) detecting
the top of the load by a detector moveable with the tape dispenser
during step a); and c) binding the load with a corrected pattern
based on the detected top of load.
12. An apparatus for binding a three dimensional load with tape,
the apparatus comprising: a turntable to rotate the load; a
carriage to carry a tape dispenser for movement along an upward
path and a downward path adjacent the load; a controller to control
the movement of the turntable and the carriage to bind the load
according to a desired pattern, wherein the controller comprises a
computer program which calculates the required turntable speed for
a substantially constant predetermined speed of the carriage over a
substantial portion of the upward path or a substantial portion of
the downward path such that the relative position of the turntable
and the carriage is such that the load is bound according to the
desired pattern.
13. The apparatus as defined in claim 12 wherein the carriage speed
is constant over an intermediate portion of both of the upward and
the downward paths to allow for acceleration and deceleration at
the extremes of the paths.
14. The apparatus as defined in claim 13 wherein the apparatus is
operable to determine predefined parameters of the load during the
binding operation and the carriage has two possible constant speeds
being a fast speed and a slow speed and wherein the controller is
arranged to operate the apparatus to apply tape at the slow speed
to apply a default pattern which is pre-programmed into the
controller and the controller is arranged to operate the apparatus
to apply tape at the fast speed according to a pattern which is
determined by the controller once the predefined parameters of the
load are determined.
15. The apparatus as defined in claim 12 wherein the apparatus is
adapted to bind a three dimensional load which is square or
rectangular and the desired pattern for the tape is broken down
into segments of quarter turns of the turntable by the controller
to determine, for each quarter turn: the required position of the
carriage to apply tape according to the desired pattern; when the
carriage will arrive at the required position; and the speed of the
turntable required to rotate the load through said quarter
turn.
16. An apparatus for binding a load with tape, the apparatus
comprising: a turntable for supporting and rotating the
three-dimensional load; a tape dispenser for dispensing tape, the
dispenser being moveable relative to the turntable and the load;
and a logistical controller arranged to control rotation of the
load and movement of the tape dispenser; wherein the controller is
arranged to operate the apparatus to dispense the tape according to
a desired pattern comprising a plurality of helical paths, each
path including at least one upward helix, a loop over the top of
the load and a downward helix giving rise to a pattern whereby the
upward and downward helixes are transversely spaced from each other
and each upward helix crosses with at least one downward helix.
17. The apparatus as defined in claim 16 wherein the apparatus
includes a data entry means for the operator to select the desired
pattern from a variety of pattern options.
18. The apparatus as defined in claim 17 wherein the data entry
means is also adapted to receive operator entry of one or more
parameters of the looping.
19. An apparatus for binding a three-dimensional load with tape,
the apparatus comprising a turntable for supporting and rotating
the three-dimensional load; a tape dispenser for dispensing tape,
the dispenser being moveable relative to the turntable and the
load; and a logistical controller arranged to control rotation of
the load and movement of the tape dispenser, wherein the logistical
controller controls the operation of the apparatus to bind the load
with tape according to a desired pattern; and means for inputting
into the logistical controller, one or more values corresponding to
one or more selected heights, wherein the logistical controller
controls the operation of the apparatus to apply substantially
horizontal over-bands over the desired pattern at the one or more
selected heights.
20. The apparatus as defined in claim 19 wherein the desired
pattern applied to the load is a helical pattern comprising a
plurality of upward and downward helixes which are spaced from each
other with at least some of the upward helixes crossing at least
some of the downward helixes
21. An apparatus for binding a three-dimensional load with tape,
the apparatus comprising: a turntable for supporting and rotating
the three-dimensional load; a tape dispenser for dispensing tape,
the dispenser being moveable relative to the turntable and the
load; and a logistical controller arranged to control rotation of
the load and movement of the tape dispenser to dispense tape onto
the load in a desired pattern, wherein the controller is programmed
to position the tape dispenser at a home position which is at a
convenient height for the user to position tape on the load and
wherein the controller is arranged to control movement of the tape
dispenser to a start position to commence application of tape to
the load in the desired pattern.
Description
RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of U.S.
Ser. No. 10/398675 entitled "Method and apparatus for wrapping a
load".
FIELD OF THE INVENTION
[0002] The present invention relates to an apparatus and method for
binding a load with tape. In particular, although not exclusively,
the invention relates to a tape binding apparatus of the type in
which a palletised load to be secured is rotated on a turntable and
the tape is dispensed from a tape dispenser which moves up and down
on an upright mast alongside the rotating load to dispense the tape
in particular patterns over the load.
BACKGROUND OF THE INVENTION
[0003] Conventionally, stretch film is used to wrap a palletised
load. The load is supported on a turntable and the stretch film is
dispensed from a roll of film which resides on a moveable carriage
which moves up and down alongside the palletised load. The carriage
advances so that the film is dispensed in a spiral. The pitch of
the spiral is such that the edges of the film overlap the previous
layer. The carriage includes a photoeye so that as it advances
upwards, the photoeye detects the top of the load so that after a
brief delay, the carriage will then commence to move downwards.
Since the pitch is chosen to enable the film to overlap, the sides
of the load will be completely enshrouded in the stretch film at
the completion of one upward and downward pass of the stretch
film.
[0004] Stretch film has inherent drawbacks in that there is
considerable wastage of material since at the destination of the
load, the film is simply cut from the load and is not reused.
Another drawback in the use of stretch film is that some products
once palletised need to breathe to allow cooling and avoid
condensation or sweating. This can lead to double handling of the
loaded pallets or loss of product from a pallet before
wrapping.
[0005] Tape dispensers have become known which apply an adhesive
tape which is stretchable to maintain tension in the tape. The
adhesiveness tends to diminish as the tape is stretched. The tape
can be applied to the load by rotating the load on a turntable and
dispensing the tape from a moveable carriage which moves up and
down alongside the load. Unlike stretch film, the carriage moves up
and down more than once, usually about four times up and down to
produce a pattern of crisscrossing upward and downward helixes.
However, unlike stretch film wrapping which enshrouds the load, the
tape must be applied with precision so that the resulting tape
pattern will effectively secure the load. The tape pattern may be
dependent upon the dimensions of the particular items in the load
as is described in our earlier application (Ser. No. 10/398675),
from which the present application is a continuation-in-part. The
contents of the earlier application Ser. No. 10/398675 are
incorporated herein by reference.
[0006] Therefore, in order to effectively bind a load with tape, a
precise pattern must be adhered to and accordingly, the overall
dimensions of the load are known in advance to produce the precise
pattern. Thus, with existing tape binding apparatus, the operator
is required to key in the height of the load and for this he will
likely need to use a tape measure. Additionally, the operator will
be required to enter an "X" value which equates to the number of
sides the load is rotated through for the inclined tape paths to
traverse from the bottom to the top. Also, in the completed
pattern, the "X" number will equate to the number of crosses formed
in tape on each side of the load. This entry of data, especially
the measuring step is time consuming.
[0007] Another issue for existing tape binding apparatus is that it
is relatively slow in comparison to conventional stretch film
wrapping apparatus. One of the reasons for this is that the tape
dispensing carriage needs to traverse up and down at least four
times in order to create the desired binding pattern. In contrast,
stretch film wrappers only need to traverse up and down once.
Furthermore, in binding a palletised load which is generally
rectangular or square in cross-section, the carriage will generally
pause to wait for the turntable to rotate to present each side of
the load to which tape is to be applied. This also slows down the
tape binding process. There are limits to which the carriage can be
moved, firstly, for reasons of operator safety. Secondly, the
carriage needs to change direction a number of times and there is
therefore a maximum speed that the carriage can travel in order to
decelerate within a reasonable time and distance.
[0008] Another particular problem encountered by tape binding
apparatus which is not so problematic with film wrappers is that of
partial top layers on a pallet. With stretch film wrapping, partial
layers are easily dealt with since the stretch film can still
cocoon around the partial layer. However, a partial layer is not so
easily handled with a relatively thin piece of tape.
[0009] It is therefore an object of the present invention to
overcome at least some of the aforementioned problems.
SUMMARY OF THE INVENTION
[0010] In accordance with a first aspect of the present invention
there is provided an apparatus for binding a three-dimensional load
with tape, the apparatus comprising:
[0011] a turntable for supporting and rotating the
three-dimensional load;
[0012] a tape dispenser for dispensing tape, the dispenser being
moveable relative to the turntable and the load;
[0013] a logistical controller arranged to control rotation of the
load and movement of the tape dispenser; and
[0014] a detector to detect the top of the load, the detector being
moveable with the tape dispenser, wherein the controller is
arranged to operate the apparatus to dispense the tape according to
a predetermined default pattern until the detector determines the
top of the load, whereafter, the controller is responsive to a
signal from the detector corresponding to the detected top of load
to operate the apparatus according to a corrected pattern based
upon the detected top of load.
[0015] The detector may be in the form of an electronic light
detector which detects reflected light. The detector may include a
light source and may detect reflected light from the load.
Alternatively, the detector may detect reflected light from a
spaced sensor. The light source may be infra-red or laser. The
detector is not limited to an electronic light detector and may be
any other kind of known limit detector.
[0016] The detector is moveable with the tape dispenser.
Accordingly, if the tape dispenser is provided on a moveable
carriage driven up and down a mast, then the detector may be
mounted on the carriage. Preferably, the detector is spaced above
the taped dispenser and as such, provides advance warning to the
controller that the tape is approaching the top of the load.
[0017] A typical pattern which may be applied to the load is a
helical pattern where the tape dispenser moves up and down relative
to the load as the turntable is driven to rotate. Accordingly, the
tape travels in an upward continuous helix and then a downward
continuous helix. Additionally, substantially level passes of the
tape may be applied to the load subsequent to each upward traverse
and also subsequent to each downward traverse.
[0018] In the abovementioned exemplary pattern, the controller
operates the apparatus to dispense the tape in the predetermined
default pattern by selecting a default pitch. The dimension of
pitch is the vertical distance between the ends of the tape on one
side of the load. In a preferred form of the invention, the
controller operates the apparatus to initially dispense tape to
create an upward helix on the load. The tape is applied at a
default pitch until the detector determines that the top of the
load has been reached. Once the controller is aware of the
dimensions of the load, the controller then operates the apparatus
according to a corrected pattern. In the exemplary helical pattern
described above, the tape will be applied to a portion of the load
between a user defined upper or lower limit. To apply the corrected
pattern, a corrected pitch is calculated so that the tape will be
applied to a whole number of side of the load as it traverses
between the upper and lower limit and vice versa.
[0019] While it has been described above that the exemplary helical
pattern may commence with an upward helix, this need not be the
case. The pattern may commence intermediate the height of the load
and first helix down before winding back up. This particular
variation may enable the tape to commence at a convenient height
for the user to save the user having to bend down to apply the tape
to the load.
[0020] The pattern applied to the load is not limited to the
exemplary helical pattern described above and other patterns may be
applied to the load. For example the helixes need not be continuous
and one or more horizontal bands may be applied during the upward
or downward traverse of the tape. Furthermore, looping over the top
of the load between the upward and downward traverse is also
included within the scope of the invention.
[0021] The controller may receive a number of user inputs through
the use of a keypad or other data entry means. The tape need not be
applied to the whole of the load and in fact the top limit of the
tape is generally spaced below the top of the load. In the looping
example, there may be a top limit of the helical pattern with still
looping over the top of the load. Furthermore, the tape may be
applied to the pallet which supports the load. Accordingly, the
pattern between these upper and lower limits may be referred to as
the pattern array. The user may input into the controller the upper
limit of the pattern array and the lower limit of the pattern
array. The user may input the upper limit by entering a value of
top drop which is defined as the distance from the top of the load.
This avoids the need to measure the overall load height.
[0022] The user may also input the pallet dimensions. It is also
possible for the user to enter a variation into the calculated
pattern. For example in the above described helical pattern there
is a whole number of crosses applied to each side of the load and
the default number of crosses (X value) is determined by the
controller. Accordingly, the user can input a variation to increase
or decrease the number of crosses on each side of the load, by way
of a whole number. The user may also input a maximum turntable
speed.
[0023] The turntable may be driven by a motor and the carriage may
be driven by another motor. The controller controls operation of
both the turntable motor and the carriage motor. Feedback may be
provided to the controller as to the turntable orientation.
Feedback may also be provided as to the height of the carriage. For
example, feedback may be provided by a detector determining the
passing of teeth of a toothed wheel.
[0024] The controller is able to calculate the array height by
determining the carriage height when the top of the load is
detected. There may be an adjustment for the offset between the
carriage height and the actual location of the detector. From this,
the lower limit dimension and the top drop are deducted to obtain
the array height. The corrected pattern is then based on the array
height.
[0025] By way of example, in the helical pattern, the number of
crosses is calculated by dividing the array height by the default
pitch and rounding this to the nearest whole number to arrive at a
value for the number of crosses (X value). The corrected pitch is
then calculated by dividing the array height by the X value.
[0026] As previously mentioned, the detector will provide advance
warning that the tape is approaching the top of the load.
Accordingly, the controller may determine an adjustment which is
required so that the tape reaches the upper limit coinciding with
the end of an inclined pass across a side of the load.
[0027] In accordance with the second aspect of the present
invention there is provided a method of binding a three-dimensional
load with tape, the method comprising: [0028] a) binding the load
with tape dispensed from a movable tape dispenser according to a
default pattern; [0029] b) detecting the top of the load by a
detector moveable with the tape dispenser during step a); and
[0030] c) binding the load with a corrected pattern based on the
detected top of load.
[0031] The above method is preferably carried out in a tape binding
apparatus, the operation of which is controlled by a controller.
The tape binding apparatus may include a turntable to rotate the
load and a vertically moveable carriage on which the tape dispenser
is provided. The controller may control the turntable and the
carriage speed to effectively wrap the load. The controller may
access stored default pattern parameters for operating the
apparatus according to the default pattern. The controller may also
receive a signal from the detector corresponding to the top of
load. The controller then uses this received information to
calculate the height of the array i.e. the portion of the load
intended to be bound and then operates the apparatus according to a
corrected pattern. Any of the features described above in
connection with the first aspect may be applied to the second
aspect of the invention.
[0032] In accordance with a third aspect of the present invention
there is provided an apparatus for binding a load with tape, the
apparatus comprising: [0033] a turntable to rotate the load; [0034]
a carriage to carry a tape dispenser for movement along an upward
path and a downward path adjacent the load; [0035] a controller to
control the movement of the turntable and the carriage to bind the
load according to a desired pattern, wherein the controller
comprises a computer program which calculates the required
turntable speed for a substantially constant predetermined speed of
the carriage over a substantial portion of the upward path or a
substantial portion of the downward path such that the relative
position of the turntable and the carriage is such that the load is
bound according to the desired pattern.
[0036] The desired pattern may be one which is predetermined i.e.
it may be a default pattern. Alternatively, the desired pattern may
be one which is calculated during the binding sequence i.e. once
the top of the load is detected, as with the first aspect of the
invention.
[0037] It will be appreciated that in the upward path of the
carriage, while the turntable rotates, the tape will be applied in
an upward helix to the load. Similarly in the downward path of the
carriage, while the turntable continues to rotate in the same
direction, the tape will be applied in a downward helix onto the
load. The carriage speed may be constant over a substantial portion
of both of these paths. Preferably, the speed of the carriage is
constant over an intermediate portion of the paths which allows for
acceleration and deceleration at the extremes of the paths.
Furthermore, the carriage may have two possible constant speeds
being a fast speed and a slow speed. The slow speed may be used to
apply the default pattern as described in connection with the first
aspect of the invention. The fast speed may be used to apply the
corrected pattern.
[0038] The turntable may be driven by a variable speed drive which
may be infinitely variable up to a maximum speed which will either
be determined by the parameters of the drive or may be determined
by a user input into the controller. The controller may provide an
analog output to the variable speed drive.
[0039] A digital output may be provided from the controller to the
carriage drive. The digital signals may be one of up, down or
fast.
[0040] In a preferred embodiment of the invention, the load
intended to be bound will be square or rectangular. The controller
may be adapted to receive user inputs of the dimensions i.e. length
and width. Accordingly, the desired pattern for the tape may be
broken down into quarter turn segments. In this manner the computer
program may calculate, for the next quarter turn of the turntable,
where the carriage is required to apply tape according to the
desired pattern and when the carriage will arrive at a particular
position given the constant speed and then calculates the speed of
the turntable required to rotate the load through the quarter
turn.
[0041] The desired pattern may not be limited to a helix up and
helix down and additionally may incorporate other features
including looping, banding and an initial home position as
described above in accordance with the first aspect of the present
invention. In particular, the step of looping takes place between
the upward path and the downward path by the tape crossing over the
top of the load at the corner instead of traversing the corner at
the sides of the load. This provides additionally securement at the
top of the load. Additionally, where the load is provided with a
sheet of flexible plastic or board at the top of the load, the
looping can be used to secure this sheet.
[0042] The feature of looping may be an operator selected option
which the operator may select through a key pad, this option being
conveyed to the controller. Once the looping option is selected, it
is applied between each upward path and downward path in the
binding sequence.
[0043] The operator may also adjust the parameters of the looping.
For example, the operator may be able to adjust the overshoot. This
is the distance above the top of the load to which the carriage
travels to apply the tape in a loop over the corner. A high
overshoot will create a loop which is more greatly spaced from the
corner than a loop resulting from a low overshoot.
[0044] In looping, the carriage still travels at a constant
predetermined speed and the computer calculates the required
turntable speed for the turntable to be in the correct position at
the conclusion of the carriage overshoot. In practice, this may
result in the turntable speed being quite slow.
[0045] In accordance with the fourth aspect of the present
invention there is provided an apparatus for binding a load with
tape, the apparatus comprising: [0046] a turntable for supporting
and rotating the three-dimensional load; [0047] a tape dispenser
for dispensing tape, the dispenser being moveable relative to the
turntable and the load; and [0048] a logistical controller arranged
to control rotation of the load and movement of the tape dispenser;
wherein the controller is arranged to operate the apparatus to
dispense the tape according to a desired pattern comprising a
plurality of helical paths, each path including at least one upward
helix, a loop over the top of the load and a downward helix giving
rise to a pattern whereby the upward and downward helixes are
transversely spaced from each other and each upward helix crosses
with at least one downward helix.
[0049] The controller may be operated in such a way that the
looping is conducted in the manner described above in connection
with the third aspect of the invention.
[0050] The operator may be able to input an overshoot parameter
into the controller to affect the looping characteristics. An
invention may also reside in a method of binding a load with tape
so as to effect looping over the top of the load.
[0051] In accordance with the fifth aspect of the present invention
there is provided an apparatus for binding a three-dimensional load
with tape, the apparatus comprising a turntable for supporting and
rotating the three-dimensional load; a tape dispenser for
dispensing tape, the dispenser being moveable relative to the
turntable and the load; and a logistical controller arranged to
control rotation of the load and movement of the tape dispenser,
wherein the logistical controller controls the operation of the
apparatus to bind the load with tape according to a desired
pattern; and means for inputting into the logistical controller,
one or more values corresponding to one or more selected heights,
wherein the logistical controller controls the operation of the
apparatus to apply substantially horizontal over-bands over the
desired pattern at the one or more selected heights.
[0052] The invention may incorporate any of the features described
above in accordance with the above aspects of the invention. In
particular, the desired pattern may be the helical pattern
described above which is applied to the substantially the full
extent of the load and may optionally include looping. The benefit
of the over-banding is that the underlying tape of the helical
pattern may be cut down to the uppermost over-band and that portion
of the tape removed. The over-banding retains the remainder of the
tape binding in place so that a portion of the load may be removed.
This makes it possible to load onto a single pallet, boxes or items
which are intended for different destinations. If there are three
destinations then two over-bands may be applied. The underlying
tape of the helical pattern is removed down to the first over-band
at the first location. At the second location, the first over-band
is removed and the tape of the helical pattern is cut to a level
above the second over-band. At the third location, all of the tape
may be cut to deliver the remainder of the load.
[0053] An invention may also reside in a method of binding a load
in a manner which produces overbands.
[0054] In accordance with a sixth aspect of the present invention
there is provided an apparatus for binding a three-dimensional load
with tape, the apparatus comprising: [0055] a turntable for
supporting and rotating the three-dimensional load; [0056] a tape
dispenser for dispensing tape, the dispenser being moveable
relative to the turntable and the load; and [0057] a logistical
controller arranged to control rotation of the load and movement of
the tape dispenser to dispense tape onto the load in a desired
pattern, wherein the controller is programmed to position the tape
dispenser at a home position which is at a convenient height for
the user to position tape on the load and wherein the controller is
arranged to control movement of the tape dispenser to a start
position to commence application of tape to the load in the desired
pattern.
[0058] The above aspect of the invention may incorporate any of the
features described in the above aspects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0059] To facilitate an understanding of the invention, reference
is made in the description to the accompanying drawings where the
invention is illustrated in several preferred embodiments. It is to
be understood, however, that the invention is not limited to the
preferred embodiments illustrated in these embodiments.
[0060] In the drawings:
[0061] FIG. 1 is a plan view of a tape binding apparatus according
to a first embodiment of the invention;
[0062] FIG. 2 is a side view of the tape binding apparatus shown in
FIG. 1;
[0063] FIG. 3 is a detailed sectional plan view showing various
components of the turntable and a drive means for driving the
turntable of the tape binding apparatus of FIG. 1;
[0064] FIG. 4 is a side sectional view of the turntable shown in
FIG. 3;
[0065] FIG. 5 is a side view of a mast assembly together with a
carriage assembly and tape dispenser of the tape binding apparatus
shown in FIG. 1;
[0066] FIG. 6 is an end view of the tape binding apparatus shown in
FIG. 5;
[0067] FIG. 7 is a plan view of the tape binding apparatus shown in
FIG. 5;
[0068] FIGS. 8 to 10 are enlarged views of FIGS. 5 to 7
respectively;
[0069] FIG. 11 is a schematic diagram illustrating various
functional components of a control system for controlling the
operation of the tape binding apparatus shown in FIGS. 1 to 10;
[0070] FIG. 12 is a side view of the mast assembly and a load
supported on the turntable showing attachment of the tape to the
load;
[0071] FIGS. 13 and 14 are a flow chart illustrating steps
performed by the control system shown in FIG. 11 to control
operation of the tape binding system shown in FIGS. 1 to 10;
[0072] FIGS. 15 to 20 show exemplary loads when bound with various
tape binding patterns by the tape binding system shown in FIGS. 1
to 10;
[0073] FIGS. 21 and 22 provide various views of each of the sides
of a load as it is bound by tape from the tape binding apparatus
shown in FIGS. 1 to 10;
[0074] FIG. 23 is a schematic view of a modified form of a tape
binding apparatus;
[0075] FIGS. 24 and 25 provide various diagrammatic views of each
of the sides of a load as it is bound with tape with the tape
binding apparatus of FIG. 23;
[0076] FIGS. 26a and 26b are diagrammatic views of two adjacent
sides of the load illustrating placement of the tape in looping
over the top of the load;
[0077] FIG. 26c is a plan view of the load of FIGS. 26a and
26b;
[0078] FIGS. 27a and 27b are diagrammatic views of two adjacent
sides of a load with a variation in the looping over the top of the
loads;
[0079] FIG. 27c is a plan view of the load of FIGS. 27a and
27b;
[0080] FIGS. 28 and 29 are various diagrammatic views of each of
the sides of a load as it is bound by tape using the step of
looping;
[0081] FIG. 30 is a perspective view of a load which is bound with
tape with the additional feature of overbanding.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0082] Referring to FIGS. 1 to 4, there is shown generally an
apparatus 2 for palletising and binding a load 18. The apparatus 2
comprises a turntable 4, a mast 8 extending vertically from and
connected to a base plate 10, a carriage assembly 12 supported on
the mast 8 for vertical reciprocating motion with respect to mast.
Carriage assembly 12 includes an arm assembly 14 and a roll
mounting assembly 16 which supports a roll of tape 80 to be
dispensed therefrom and wound around the load 18 located on the
turntable 4. The arm assembly 14, roll mounting assembly 16 and
roll 17 form part of a tape dispensing arrangement 13 for applying
tape to the load 18. Both the arm assembly 14 and the roll mounting
assembly 16 may be integrally formed with the carriage assembly 12
or connected directed to the carriage assembly 12. A pre-tensioning
assembly 20 is connected to the carriage assembly 12, and acts to
pre-tension the tape dispensed from the tape dispensing means 13.
The tape is preferably #8884 or #8886 manufactured by Minnesota
Mining & Manufacturing (3 M) Company, or tape as disclosed in
the specification of U.S. Pat. No. 5,496,599 in the name of 3 M.
Details a pre-tensioning assembly 20 are disclosed in our earlier
application Ser. No. 10/398675.
[0083] The turntable 4 is adapted for rotational movement about a
central hub 24. The turntable 4 includes a top plate and a bottom
plate. Located between the top and bottom plates is a belt 28 which
drives a pulley 26. The belt 28 is driven by a drive wheel/pulley
30 driven by an electric motor 32, or other turntable drive means.
In an alternative embodiment, the pulley may comprise a circular
sprocket 26 which has teeth adapted to engage an endless drive
chain 28 which passes around a sprocket 26.
[0084] Referring to FIGS. 5 to 10, the vertical reciprocating
motion of the carriage assembly 12 is enabled by a sprocket and
pulley arrangement mounted at opposing ends of the mast 8. A drive
chain 42 is attached to part of the carriage assembly 12. An
electric motor 44 or other carriage assembly drive means causes the
rotational movement of a drive sprocket 46 located at a lower end
of the mast 8 by means of drive shaft 48. A pulley 50 is mounted to
the upper end of the mast 8. Alternately, the pulley 50 may be
replaced by a sprocket which includes teeth to engage the chain
42.
[0085] The carriage assembly 12 includes a carriage tube 52 adapted
to fit around the periphery of the mast 8 to enable slidable
movement therealong. The movement of the carriage assembly 12 along
the mast 80 is enabled by connection of the drive chain 42 to the
carriage tube 52 by way of suitable connection such as depending
lugs or flanges 54 and 56 located on the outer surface of the
carriage tube 52.
[0086] The movement of the carriage assembly 12 vertically up and
down the mast 8, in conjunction with the rotation of the turntable
4, enables the tape 80 to be wound around the palletised load 18 in
a helical or circular manner. Particular patterns of the
helical/circular binding are able to be applied to the load 18 by
controlling the rotational movement of the turntable 4 and the
movement and position of the carriage assembly on the mast 8.
[0087] A control panel structure 67, shown in FIG. 2, is connected
to the mast assembly 8 for attachment of an electronic circuit
board and a display 68. Electric cables run to and from the circuit
board 68 and from sensors 60, located near the toothed wheel 62,
and 64 located near the toothed wheel 66. The toothed wheel 60 is
mounted to the turntable 4 about the central hub 24, whilst the
toothed wheel 66 is mounted about the shaft of the motor 44. The
sensor 60 is mounted adjacent the toothed wheel 62 to sense the
number of teeth of the toothed wheel passing in front of the sensor
to thereby provide an indication of the angular position or
rotation of the turntable 4. The sensor 64 is mounted adjacent the
toothed wheel 66 in order to sense the number of teeth passing on
the toothed wheel 66 before the sensor 64 in order to indicate the
displacement of the carriage assembly 12 along the mast 8.
[0088] The sensors 60 and 64, and corresponding toothed wheels 62
and 66 form part of a control system 100 for controlling the
rotation of the turntable 4 and the movement of the carriage
assembly up and down the mast 8, to thereby control the binding
process of the palletised load 18.
[0089] As can be seen in FIG. 11, the sensors 60 and 64 form part
of a control system 100 for controlling operation of the motors 32
and 44. Power is supplied from the mains supply 102 to a Variable
Frequency Drive (VFD) 106 adapted to drive the motor 44 controlling
carriage assembly movement, and VFD 106 driving the motor 32
controlling turntable rotation. Power is also supplied to carriage
drive 104. The VFD 104 and 106 are supplied with 240 volts AC from
the mains supply 102.
[0090] A controller 108 is supplied with 12 volts DC from the mains
supply 102 through a transformer 110. The controller 108 is housed
in the control panel structure 67 attached to the mast assembly 8.
Control signals are sent from the controller 108 to the control
signal input terminals of the VFDs 104 and 106 in accordance with
instructions fetched from the PROM 112 storing a computer program.
The control signals supplied by the controller 108 are dependent
upon the output signals of the sensors 60 and 64, which are
supplied to the controller 108. A keypad 114 is provided to enable
the entry of data by the operator, whilst a display 116 and other
associated indicators display selected information to the
operator.
[0091] Typically, the keypad 114 and display 116 are accessible
through the panel 68 shown in FIG. 2.
[0092] Each of the sensors 60 and 64 is adapted to transmit a pulse
every time a tooth, respectively of toothed wheels 62 and 66,
passes in front of the sensor. The number of pulses that must be
received by the controller 108 from the sensor 60 to correspond to
a 90.degree. rotation of the turntable 4 is pre-stored in the
controller 108 so that when an internal counter reaches that number
of pulses, the controller is able to detect a quarter turn rotation
of the turntable 4. Similarly, the movement of the carriage
assembly 12 up and down the mast 8 and the number of pulses emitted
by the sensor 64 are calibrated that by counting the number of
pulses received from the sensor 64 the controller 108 is able to
determine the distance travelled along the mast.
[0093] In FIG. 12 there is shown a side view of the load 18
supported by a pallet 23. The pallet and load are mounted on the
turntable 4. In this example, the load 8 includes 4 layers 19, each
consisting of a series of sixteen containers 21.
[0094] The length of the load 18 is a fixed distance L.sub.p,
whilst the distance from the rear of the load 18 to the point on
the tape dispensing means 20 from which the tape is dispensed is
also a fixed distance L.sub.c. In this example, a pattern of tape
is intended to be applied to the load 18, with the tape 80 running
between points 25 half way along the height of each box 21. In the
position shown in FIG. 12, it is desired for the tape 80 to run
from a point halfway up the corner of the left most container of
the lower layer of the load 18 to a point halfway up the corner of
the container the second lowermost layer. The vertical distance
between points 25 is referred to as "pitch".
[0095] The controller 108 may be programmed with data corresponding
to the various distances L.sub.p and L.sub.c and the pitch H.sub.b.
However, it is preferred that the operator will enter certain
dimensions which include the pallet dimensions of length L.sub.p
and breadth (not shown) and height H.sub.l. However, it is more
common practice that the operator enters a value of "top drop". Top
drop T.sub.d is the distance from the top of the load down to the
point which the operator wants to be the uppermost limit of the
tape. In this example, that would correspond to the distance from
the top of load 18 down to the point 25 in the uppermost layer.
Generally, the dimension of top drop corresponds to half the height
of the top layer. The operator may also enter the minimum tape
height which is the height from the bottom of the load to the
lowest run of tape H.sub.min (see FIG. 15) although a default value
may be provided. The operator may also enter the height of the load
and an X value which equates with the number of crosses made on
each side of the load or alternatively equates with the number of
sides of the load to be presented for the tape to traverse from
H.sub.min to reach the upper limit defined by top drop.
[0096] Thus, the controller 108 can calculate from the entered
values of load height, top drop and minimum tape height, a value of
array height A (see FIG. 15) which is the height of the portion of
the load to be bound with tape. By dividing this value by the X
value, the controller can determine the pitch H.sub.b. Generally
speaking, the distance L.sub.c will be already programmed and not
necessary to be entered by the operator. Instead of entering the X
value, the operator may simply enter the number of layers in the
load. Alternatively, the operator need not enter an X value or the
number of layers, instead, the controller could calculate a pitch
from the array height and the dimension of top drop.
[0097] Alternatively, the operator could enter the height of each
layer and the number of layers. From this, a load height can be
determined (assuming a default pallet size). A default top drop
based on half the height of each layer could thus be used to
determine array height. Thus determination of pitch could be made
on the information about the height of each layer, given the
desirability of crossing points 25 midway along the height of each
layer.
[0098] Thus, the characteristics of the load may be entered into
the controller through the keypad using various different aspects
of the load including height of the load, top drop, height of each
layer, number of layers, pallet dimensions of length and breadth,
desired number of crosses (X value). Which characteristics are
required to be entered by the keypad will depend upon the
particular programming of the apparatus. There is not one
particular combination of parameters which are essential to the
invention.
[0099] Additionally, the controller may be programmed with a number
of default values including L.sub.c, H.sub.min, pallet size. The
controller may use these default values or there may be a manual
override for values entered from the keypad. From the default
values and/or the operator entered values, the parameters of the
binding pattern can be determined by the controller.
[0100] From the data corresponding to the distances L.sub.p,
L.sub.c and H.sub.b, the controller 108 is able to determine the
distance H.sub.c through which the tape dispensing apparatus must
travel for the tape to be inclined at pitch H.sub.b across each
side of the load. In the exemplary arrangement shown in FIG. 12,
the load 18 and pallet 23 have four sides, and a predetermined
pattern of tape 80 is applied to the load 18 by driving the
turntable 4 through a series of 90.degree. rotations, and by
driving the carriage assembly 12 up and down the mast 8 to
predetermined positions prior to the completion of each of those
90.degree. rotations.
[0101] To explain a typical binding sequence, FIGS. 21 and 22 show
the entire binding sequence for a four-sided load 500 consisting of
two layers 501 and 502 stacked on a pallet 503. The letters A, B, C
and D refer to the sides of the load 500. The exemplary load
positions referenced 401 to 432 in these Figures demonstrate the
manner in which a multiple-X pattern is applied to the load 500 by
the tape binding apparatus 2. Initially, the operator from the
keypad selects an X value of 2 to be applied to the load 500 and
enters the top drop 504 and minimum tape height 505.
[0102] Once tape is applied to the load 500 in position S, the
turntable is rotated through 90.degree. and the carriage assembly
12 driven so that the tape dispensing means 20 dispenses tape at
the minimum tape height 505. Since the X value is 2, the height at
which the helixes of tape will cross at the edges of the load 500
will be midway between the top drop and minimum tape heights 504
and 505. In position 402, the carriage assembly is driven so that
the tape is dispensed from a position higher than this intermediary
X point 506 in order to ensure that tape crosses the corner at the
intermediate height 506. In position 403, the load 500 is again
rotated and the carriage is driven to a height in order that tape
can be applied on face C from the intermediary X point height 506
to the top drop height 504. The carriage will thus overshoot the
top drop height 504 to apply tape at top drop height 504.
[0103] At position 404, the carriage assembly is driven back down
to the top drop height 504 in order to dispense tape horizontally
and apply a portion of the top band at the top drop height 504. In
position 405, the carriage assembly 12 is driven down the mast 8 to
a position below the intermediate X point height 506 in order that
tape can be applied on face A from the top drop height 504 to the
intermediate X point height 506.
[0104] In position 406, the turntable 4 once again rotates and tape
is applied between the intermediate X point 506 height and the
lower portion of the load 500. In this case, the carriage assembly
12 is unable to be driven so that the tape dispensing means is
below the height of the pallet 503 and the tape is only able to be
applied at the minimum tape height 505 upon a further rotation of
the pallet as shown in position 407. In position 408, the load is
rotated a further 90 on the turntable 4 and a portion of a band is
applied at the minimum height 505. Positions 409 to 432 illustrate
the manner in which the tape is applied to complete the pattern to
the load 500. In this pattern, it will be appreciated that tape is
applied to the load 18 in a series of spaced upward and downward
helixes positioned so that the helixes cross at predetermined
locations.
[0105] It will be appreciated that having entered data indicative
of the pallet and load and optionally certain characteristics of
the pattern to be applied to the load and having been programmed
with the known physical dimensions of the carriage assembly, tape
dispenser and displacement between the mast 8 and the centre of the
turntable, the controller 108 is able to operate the motors 32 and
44 in order to apply the tape in a desired pattern to contain the
load 500.
[0106] FIGS. 13 and 14 illustrate a series of steps that the
computer program stored in the PROM 112 causes the controller 108
to undertake in order to apply a pattern to the load 18 such as the
pattern described above in connection with FIGS. 22 and 23. At step
200, a program corresponding to a desired pattern is loaded into
the PROM 112. At step 202, data corresponding to the load and
pallet dimensions, and data defining the characteristics of the
particular pattern to be applied to the load, are entered via the
keypad 114 or default values are loaded from memory. At step 204,
the program is then activated by the operator. At step 206, the
controller 108 fetches the first instruction of the computer
program. This instruction causes the motor 32 to be activated to
drive the turntable sprocket 26 in a clockwise direction. At step
208, the controller counts a predetermined number of pulses from
the sensor 60 corresponding to a 90.degree. rotation of the
turntable. At step 210, once the 90.degree. rotation of the
turntable has occurred, the controller fetches instructions for the
second cycle of the program. In this step, the controller again
energises the motor 44 to drive the carriage assembly 112 to a
desired position along the mast 8, and subsequently causes a second
90.degree. rotation of the turntable 4 to occur by energising the
motor 44. Once again, output signals from the sensor 60 and 64 are
used to confirm when the 90.degree. rotation has occurred and when
the carriage assembly 12 has been displaced to a desired
position.
[0107] Typically, predefined patterns are applied to the load 18 by
binding the tape 80 around two or more faces of the load 18 in a
generally upward direction, and then applying the tape to two or
more faces of the load 18 in a generally downward direction.
Horizontal bands may optionally be applied between the upward and
downward application of the tape. Accordingly, at step 212, the
controller determines whether more than X cycles have occurred,
where X corresponds to the number of sides to which the tape is to
be applied in a generally upward direction. Accordingly, at step
112 the controller determines whether more than X cycles have
occurred. If not, the turntable 4 is again rotated, and the
carriage assembly 12 is driven in the upward or positive direction
at step 214, prior to the fetching of the instructions for the next
cycle.
[0108] However, if more than X cycles have been performed,
instructions for the next cycle are fetched at step 216. In order
that a horizontal band is applied to an uppermost layer of the load
18, the carriage assembly 12 is not driven, but the turntable 4 is
caused to rotate through 90.degree., as sensed in step 218. At step
220, instructions for the next cycle are fetched. Once again, in
order to apply a horizontal band at the uppermost layer of the load
18, the turntable is driven through 90.degree., as sensed in step
222.
[0109] At step 224, instructions are fetched for the following
cycle. In this example, these instructions correspond to a first
cycle in the application of tape 80 to the load 18 in a generally
downward sense. The predetermined pattern to be applied to the load
18 includes X such cycles, and accordingly at step 226, a
determination is made as to whether these X cycles have been
performed. If not, the carriage assembly 12 is driven down the mast
8 by causing the motor 44 to be driven in the opposite direction.
In addition, the motor 33 is caused to drive the turntable 4
through another 90.degree. rotation. Once it has been detected at
step 228 that the carriage assembly 12 has been driven down to a
desired position and that the turntable 4 has been rotated through
90.degree., instructions for a subsequent cycle are fetched. The
tape is continued to be applied to the load 18 in this manner until
a desired predefined pattern has been applied to the load.
[0110] Various patterns may be applied to the load 18 as shown in
the FIGS. 15 to 20. Different predefined patterns may be applied to
the entirety of the load 18. Alternatively different predefined
patterns may be applied to separate portions of the load 18. The
patterns may simply vary because of the different load parameters
entered into the keypad by the operator. Alternatively, different
pattern options may be selected by the operator.
[0111] Another example of the multiple X pattern shown in FIGS. 21
and 22, is illustrated in FIG. 15. In this embodiment, the helixes
cross at the corners of the load at the mid height of the layers.
The load 300 includes 4 layers 301 to 304. Each of the corners of
each layer 301 to 304 is contained by an "X" formed from the
crossing of two portions of tape. Accordingly, each layer is fully
contained in this predefined pattern. The X value of this pattern
is thus 4. This pattern is an exemplary helical pattern, the
characteristics of which are determined by the load parameters
entered by the operator through the keypad.
[0112] An alternate pattern is shown in FIG. 16. This pattern is
referred to by the applicant as "banding", and enables a series of
horizontal bands to be applied around the load 300. The required
band heights may be chosen by the operator. In this instance, bands
306 and 307 are applied around the uppermost layer and the second
lowermost layer of the load. The controller 108 causes the carriage
assembly 12 to be driven between the two positions required to
apply the two bands 306 and 307, so that an incline of tape 308 is
applied between the bands as the tape fleets up or down between
banding levels.
[0113] FIG. 17 illustrates another variation to banding, known as
"overbanding". This is an option which may be selected by the
operator through the keypad. The pattern of FIG. 17 is applied as
per the helical pattern of FIG. 15. At the conclusion of the
helical pattern, the overbands are applied over the helical
pattern. In FIG. 17, two overbands 500 and 501 are shown. The
overband 500 is applied to the layer 304. The overband 501 is
applied to the layer 303. It is possible for the operator to select
the height of the overbands. The overband 500 is applied initially
by an inclined tape path from the conclusion of the helical pattern
at H.sub.min up to the desired height. The overband 500 is then
applied with the carriage maintained at this height for at least a
whole revolution. The second overband 501 is then applied by
inclining the tape up 1/4 revolution to the required height and
making the second overband 501. For the sake of clarity, the
inclined tape paths for each quarter revolution to reach the
desired heights of the overbands 500, 501 are not shown in FIG.
17.
[0114] The benefit of overbanding is that the portions of the tape
made according to the default pattern can be cut above the second
overband 501. The presence of the overband 501 will mean that the
remaining tape wound according to the helical pattern will not
unravel. With the tape cut above the second overband 501, the top
two layers 301, 302 can be removed. The pallet can then be
transported to another location where it is desired to remove the
layer 303 from the pallet. To achieve this, the overband 501 may be
cut and the tape cut down to above the first overband 500, thus
freeing the layer 303 from the tape binding. The load 300 may then
be transported to yet another location where all the tape may be
cut to remove the lowermost layer 304.
[0115] As previously mentioned, an operator can select the X value,
namely the number of sides traversed by inclined sections of tape
from the minimum tape height to top drop. Unlike the bound load
illustrated in FIG. 15, it is sometimes not necessary to place an
"X layer" on each layer of containers in a load in order to achieve
containment of the load. Light loads or shallow containers may
require an "X" only every second or third layer of containers. This
is because such a pattern will result in steeper angles on the
inclined section of tape. This results in a greater downward force
component tending to bind the load to the pallet.
[0116] As shown in FIG. 18, a single band of tape, or a top strap,
may be applied to the load above the main pallet load to contain
items placed on the load as a partial layer. For example, in the
last few cartons of a production run there may be insufficient
quantities of cartons to make up a full layer. Typically, the top
strap is constructed at the start of a pattern sequence. In this
way, the load integrity is retained if the partial layer is
removed. The top strap option may be selected via the keypad and
the top strap height may be input manually via the keypad.
[0117] Should the operator wish to apply the banding pattern shown
in FIG. 19 to the load 300, the operator selects the banding option
through the keypad, and enters the total number bands to be applied
to the load 300 as well as the height of each band, and the start
and finish height of the tape attachment points. On initialisation,
the carriage assembly travels to the start height and stops in
order that the operator can manually apply the tape to the load
300. Once applied, the turntable rotates to apply the first band at
the top height to the load 300, and then moves to the next band
height to apply the second band, the tape fleeting between the
first band height and the second band height around the exterior
surface of the load 300. The banding process continues until the
lower most band is applied to the load.
[0118] Another pattern that may be applied to the load 300 is known
by the applicant as "looping". As seen in FIG. 20, in this pattern,
tape is applied over the top corners of a load in order to cover or
secure each edge of the load. Looping is found to be particularly
useful where a number of flat sheets or containers, for example,
are stacked and it is difficult to effectively provide multiple
patterns to the side faces of the stack flattened boxes. Typically,
the looping pattern is applied by the tape in a downward manner and
in a sidewards manner to secure the flattened boxes or like stacked
items.
[0119] FIGS. 28 and 29 more accurately reflect the steps required
to achieve a looping pattern. In the example of FIGS. 28 and 29,
the X number is three. It can be seen that the process commences as
would be expected with a three X pattern up to step 706. However,
at step 707, instead of traversing downwardly, the carriage moves
to a distance D.sub.o above the top of the load which is referred
to as "overshoot". This causes the tape to pass over the top of the
load, instead of traversing the corner around the two sides C, D.
The operator has the opportunity to input a value for overshoot
through the keypad. The controller will ask for an overshoot value
once the looping option is selected.
[0120] FIGS. 26 and 27 show the effect of changing the value of
overshoot. In FIG. 26, a smaller overshoot D.sub.1 is entered by
the operator. The choice of overshoot effects the positions 801 and
802 where the tape crosses between the sides of the load and the
top of the load. As can be seen in FIG. 26c, a smaller overshoot
results in a relatively shallow loop.
[0121] In FIG. 27, a larger overshoot D.sub.2 has been selected
which will result in crossing points 803 and 804 producing a deeper
loop across the corner as shown in FIG. 27c.
[0122] It will be appreciated that the carriage needs to travel a
considerable distance in order that the tape be applied from the
top of the load to the crossing point 805 as shown in FIG. 26b.
Thus, if the carriage speed is maintained constant for the duration
of the binding pattern, the turntable speed will be relatively slow
for this portion of the pattern. The control of the relative
turntable and carriage speeds is explained further in conjunction
with FIG. 23.
[0123] FIG. 23 shows in schematic form a modified version of the
tape binding apparatus 2'. The tape binding apparatus 2' has a
number of features in common with the tape binding apparatus shown
in FIGS. 1 to 12. Accordingly, like numerals reflect like parts.
However, where the parts have been adapted to conform to the new
embodiment, a prime symbol (') will be used to indicate a
modification to that part.
[0124] The mechanical aspects of the tape binding apparatus 2' may
be substantially similar to that of the tape binding apparatus 2 in
that it includes a turntable 4 with a toothed wheel 62. The sensor
60 determines the passing of the toothed wheel and pulses are
counted by controller 108'. A mast 8 with a moveable carriage 12
driven via a drive chain 42 is provided. The carriage 12 carries a
roll of tape 17.
[0125] Additionally, the carriage includes a detector 900 in the
form of a photoeye which projects a beam of infrared light in a
substantially horizontal direction towards the load. The photoeye
900 is able to detect light which is reflected back from the load
and can thus accordingly detect the presence of the load. The
photoeye 900 is attached to the carriage 12 and thus moves with the
carriage 12. The photoeye 900 will thus detect when the carriage 12
has moved beyond the top of the load. Through the use of photoeye,
the top of the load will be detected automatically and accordingly,
it will not be necessary for the operator to measure the height of
the load and key this in through the keypad.
[0126] The carriage motor 44' has associated therewith a toothed
wheel 66. The sensor 64 is mounted adjacent the toothed wheel in
order to sensor the number of teeth passing on the toothed wheel
66. pulses are fed to the controller 108' where they are counted to
determine the displacement of the carriage 12 along the mast 8. A
sensor 902 is also mounted adjacent the toothed wheel 66 in order
to determine the direction of rotation of the toothed wheel 66.
Accordingly, the sensor 902 is able to verify whether the carriage
is travelling up or down.
[0127] A lower limit sensor 906 is provided to detect when the
carriage is at the lower extremity of the mast. The carriage cannot
drive below this lower extremity. The bottom limit sensor is used
to zero the count from the sensor 64 which provides an indication
of the carriage position on the mast.
[0128] A mast top limit sensor 904 is provided to indicate that the
carriage is at the upper extremity of the mast 8. The carriage
cannot drive above the upper extremity.
[0129] The keypad allows the operator to key in various load
parameters as well as selected pattern parameters. In this
embodiment, these include the minimum tape height H.sub.min, top
drop T.sub.d, pallet dimensions of length L.sub.p and breadth.
Additionally, the operator may input an incremental X number. This
is the variation to the default X number which would be
automatically determined by the machine given the pattern selection
and load parameters. For example, the operator may key in plus 1
which would result in an additional X applied to the load. Plus 2
will result in two additional Xs. Minus 1 will result in a lesser
number of Xs etc. The operator may alternatively select the default
setting.
[0130] The operator may also key in the maximum speed of the
turntable. The turntable will not rotate above this speed. The
turntable speed is automatically calculated (as will be explained).
Thus, if the calculated value exceeds the maximum speed entered by
the operator, the turntable will run at maximum speed.
[0131] The above parameters which are entered by the operator tend
to be based on the type of product being bound not the actual load
being bound. For example, in order to bind a load of bottles set on
trays in layers, the minimum tape height and pallet dimensions may
be determined by the type of pallet that the bottles are typically
loaded onto. Top drop will be influenced by the shape of the
bottles and likewise X number. The maximum speed will reflect the
maximum speed that the turntable can be rotated without the bottles
falling off the load. Thus, once these parameters are set by the
user, they need not be changed from load to load.
[0132] The operator may also key in other parameters e.g. selection
of looping or banding etc. Importantly, the actual load height does
not need to be keyed in as this is automatically determined by the
photoeye 900.
[0133] Thus it can be seen from FIG. 23 that the controller 108'
receives inputs from the turntable sensor 60, the top limit sensor
904 and the bottom limit sensor 906, the photoeye 900, the carriage
position sensors 64 and 902 and the keypad 67. The controller 108'
may conduct calculations based on the inputs in order to bind the
load with tape. Based on these calculations, the controller 108'
will generate outputs to the turntable speed drive 106 to drive the
turntable motor 32 and to the variable speed drive 104' of the
carriage to drive the carriage motor 44'. The infinitely variable
speed drive 106 receives an analog signal from the controller 108'
to drive the variable speed motor 32.
[0134] The variable speed drive 104' for the carriage drives the
carriage motor 44' at either of two speeds i.e. either fast or
slow. Furthermore, the carriage motor 44' may be driven in either
direction resulting in the carriage travelling up or down. There
are three outputs from the controller 108' to the variable speed
drive 104'. These include up, down and fast. If there is a fast
output from the controller then the carriage will be driven at the
fast speed. Otherwise, the carriage will drive at the slow speed.
These fast and slow speeds may be inherent in the variable speed
drive 104'.
[0135] The diagrams of FIGS. 24 and 25 show the sequence of
applying tape to a load using the apparatus of FIG. 23. In step
601, the operator attaches the tape to the load and presses the
start key on the keypad. The carriage 12 then drives to the lower
extremity of the mast where it stops. The mast proximity counter
associated with sensor 64 is then zeroed. The carriage then drives
up to the minimum tape height as input by the operator and
stops.
[0136] In step 602, the turntable begins to rotate. After a 1/4 of
a turntable revolution, as shown in step 603 the carriage begins to
ascend at a slow speed. However, as the carriage begins the binding
sequence at the bottom of the mast 6, the photoeye 900 has not
detected the height of the load and thus the appropriate
calculations to determine pitch cannot be done by the controller
108'. Accordingly, the tape is applied at a default pitch. This
default pitch will depend upon the incremental X number. If the
incremental X number is the default factory setting, then the
default pitch P.sub.d will be 330 millimeters. The following sets
out the default pitches P.sub.d, based on the operators selected
incremental X number: [0137] X number plus 2, tape pitch: 250
millimeters [0138] X number plus 1, tape pitch: 280 millimeters
[0139] X number F, tape pitch: 330 millimeters [0140] X number
minus 1, tape pitch: 400 millimeters [0141] X number minus 2, tape
pitch: 500 millimeters
[0142] The above default pitches are merely examples and different
values could be provided where the turntable and/or carriage speeds
are altered.
[0143] The carriage will travel upward to apply the tape at the
default pitch until the photoeye 900 detects the top of the load.
The photoeye 900 is a sufficient distance above the tape dispenser
apparatus in order that the photoeye will detect the top of the
load before the tape reaches the top drop. When the photoeye
detects the top of the load in step 605, the controller 108' reads
the mast pulse count, thus measuring the height of the load. By
deducting the top drop and the minimum tape height, the controller
can determine the array height. Once the array height is known, the
corrected pitch H.sub.b can be determined. The corrected pitch
H.sub.b is determined by dividing the array height by the default
pitch. The resultant number is then rounded to the closest whole
number to obtain the X number. The corrected pitch H.sub.b is then
derived by dividing the array height by the X number. This can be
represented as A/P.sub.d=Z
[0144] Round Z to nearest whole number (X) H.sub.b=A/X
[0145] Thus, as shown in steps 607, 608 and 609, the tape will be
applied to each side of the load at a corrected pitch H.sub.b.
[0146] However, it will be appreciated that in the step 603, 604
and 605, the application of tape at the default pitch will hardly
ever coincide with the top drop T.sub.d at the top of the upward
helix. Accordingly, some adjustment will be required for the tape
to reach the top drop position. When the photoeye detects the top
of the load, as described above, the controller 108' will be able
to determine the array height, and from this the required number of
tape crossings at the default pitch for the tape to reach this tape
height. Thus the controller can determine how far the load should
rotate until the required side of the load is presented for tape to
be applied. At the time of detecting the top of the load, the
controller 108' reads the turntable pulse count which determines
the orientation of the turntable 4 from information supplied by
sensor 60. The pulse count will enable the controller to determine
the actual orientation of the turntable. Thus, the controller will
control the turntable to continue to rotate until the required face
of the load is presented which coincides with the top of the tape
ascent.
[0147] If the turntable is already presenting this face, binding as
per the corrected pitch will start immediately. If the required
face is yet to be presented the turntable will continue to rotate.
The example shown in sequence step 606 shows this situation where a
small increment in tape height is required in order to reach top
drop. This tape is applied at an adjusted pitch P.sub.a. If however
the required face is already being presented when the top of the
load is detected, then an adjustment may be required in step 605 if
the remaining distance to reach top drop is less than the default
pitch. Accordingly, in step 605 the pitch would be less than the
default pitch shown. In this eventuality, in step 606, the tape
would be applied level.
[0148] From step 607 onwards, the apparatus continues to bind the
load according to the corrected pitch resulting in a corrected
pattern applied to the load. It will be appreciated from FIGS. 24
and 25 that the tape goes up and down four times in order to bind
the load. One of these ascents will be according to a default
pattern and a default pitch, whereas the remaining ascents and all
the descents will be according to the corrected pattern at the
corrected pitch. Thus, 1/8.sup.th of the binding pattern will be at
the default pitch whereas 7/8.sup.th of the binding patterning will
be at the corrected pitch.
[0149] From step 607 onwards, the carriage travels at the fast
speed. It is to be understood that the carriage only has two speed
options being fast and slow and both the fast speed and the slow
speed are substantially constant apart from the necessary
deceleration and acceleration required when transitioning from up
to down.
[0150] Given that the carriage travels at a constant speed, it is
thus necessary for the turntable to travel at variable speeds in
order that the pattern may be applied to the load in the desired
manner. At the default pitch, the required positions for the tape
dispenser at each quarter revolution can be determined. Likewise,
once the corrected pitch has been calculated, the required
positions for the carriage at each quarter revolution of the
turntable will be known. The controller 108' thus calculates the
required speed for the turntable so that it travels exactly 1/4
revolution in the time taken for the carriage to travel from one
destination to the next. The turntable speed calculation means that
the carriage will not actually stop at the required position.
Rather, a constant speed will be maintained for each ascent and
descent (subject to acceleration and deceleration at the extremes).
As the distance between carriage destinations will vary, depending
upon whether it applies sequential inclined runs of tape or
horizontal bands of tape, the turntable's speed will continually
adjust itself accordingly. For example, when horizontal runs of
tape are applied in banding or at the bottom of the load, the
distance to the next carriage destination will thus be small (or
zero in the case of two sequential horizontal runs of tape). The
calculated turntable speed will thus be high. In such a case, the
turntable will rotate at the maximum speed which was input by the
operator. This method of speed control results in the absolute
minimum cycle time because it enables the carriage to run at the
fastest possible safe speed i.e. a speed which is not dangerous and
also allows appropriate stopping at the upper and lower limits as
required. Thus, the turntable adjusts to suit this maximum possible
speed. This is a great saving in the binding time for a load over
existing methods because in existing methods the speed of the
carriage (which needs to travel up and down at least four times) is
the limiting factor.
[0151] In step 637 shown in FIG. 25, the turntable slows to
predetermined creep speed and then stops at the same rotational
position from which it started.
[0152] FIG. 30 illustrates a variation which may be applied to any
of the binding sequences illustrated in FIGS. 21, 22, 24, 25, 28
and 29. Instead of the operator needing to bend over to apply the
tape to the base of the load, there is a programmed "home position"
920 for the carriage which is at an appropriate height for the
operator to grab the end of the tape and apply it to the load at
that height. This saves the operator from having to bend down.
[0153] It will be understood that the invention disclosed and
defined in this specification extends to all alternative
combinations of two or more of the individual features mentioned or
evident from the text or drawings. All of these different
combinations constitute various alternative aspects of the
invention.
* * * * *