U.S. patent application number 11/221405 was filed with the patent office on 2007-12-20 for package wrapping method and apparatus.
This patent application is currently assigned to Met-Tech Corp.. Invention is credited to Michael E. Miller.
Application Number | 20070289253 11/221405 |
Document ID | / |
Family ID | 32029282 |
Filed Date | 2007-12-20 |
United States Patent
Application |
20070289253 |
Kind Code |
A1 |
Miller; Michael E. |
December 20, 2007 |
Package wrapping method and apparatus
Abstract
A semi-automatic gift or package wrapping method and apparatus
is disclosed. The apparatus includes a machine frame that provides
a work surface with measuring and wrapping sections. A sheet feed
and cutting mechanism feeds paper from a role in two steps with a
time pause in between for enabling a user or operator to partially
wrap the package with part of the first section of dispensed paper
web. Thereafter, the second section of paper web is dispensed and
the web cut transversely at a trailing edge. Multiple selectable
supply rolls are optionally provided, or a single roll machine can
be used. Longitudinal cutters trim the sides of the paper to obtain
a custom desired width for the full cut sheet. A user interface
display controls machine functions such as start, continue and
sheeter. In the sheeter mode, a selected number of sheets of a
selected size can be dispensed and cut for use at another
workstation to warp other boxes of known uniform size (i.e. shirt
boxes at a department store).
Inventors: |
Miller; Michael E.; (South
Beloit, IL) |
Correspondence
Address: |
GARVEY SMITH NEHRBASS & NORTH, LLC
LAKEWAY 3, SUITE 3290
3838 NORTH CAUSEWAY BLVD.
METAIRIE
LA
70002
US
|
Assignee: |
Met-Tech Corp.
Meridian
MS
|
Family ID: |
32029282 |
Appl. No.: |
11/221405 |
Filed: |
January 9, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10256468 |
Sep 27, 2002 |
6938397 |
|
|
11221405 |
Jan 9, 2006 |
|
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Current U.S.
Class: |
53/218 |
Current CPC
Class: |
B65B 67/10 20130101;
B65B 2210/04 20130101; B65B 11/18 20130101; B65B 59/001 20190501;
B65B 11/004 20130101; G06Q 10/043 20130101; B65B 67/08
20130101 |
Class at
Publication: |
053/218 |
International
Class: |
B65B 11/02 20060101
B65B011/02 |
Claims
1-20. (canceled)
21. A package wrapping apparatus for wrapping packages of random
sizes, comprising: a) a frame; b) a work surface supported by the
frame that holds one or more paper supply rolls; c) a measuring
station at the work surface that measures a package to be wrapped,
the measuring station including a stop that enables a user to
manually place each package of a series of packages in the same
place each time a package is to be measured; d) a user interface
display that includes a keypad with a plurality of keys for
initiating measuring, sheet feeding, and sheet cutting operations;
e) a plurality of cutters that include longitudinal and transverse
cutters for cutting a sheet of paper to be used for wrapping a
package as part of said cutting operation; f) rollers for feeding a
web of paper from the paper supply roll; and g) an adjustment
mechanism that adjusts the cutter positions relative to the paper
supply roll so that a sheet can be cut from the web that is of a
selected size and shape that is large enough to envelop the package
to be wrapped absent substantial waste.
22. The package wrapping apparatus of claim 21 wherein the stop
includes a pair of stop members that engage two side walls of the
package to be measured at positions spaced about ninety degrees
apart.
23. The package wrapping apparatus of claim 21 wherein the paper
web includes two sections that are fed by the rollers one section
at a time.
24. The package wrapping apparatus of claim 23 wherein the user
interface display has a continue key that must be depressed to
initiate feeding of the second section.
25. A package wrapping machine for wrapping boxes of random,
unknown sizes, comprising: a) a frame having a work surface with
measuring and wrapping sections and at least one roll of wrapping
paper mounted on the frame to unwind a paper web therefrom; b) an
index position on the work surface measuring section for accepting
a box of an unknown size and determining the dimensions thereof; c)
cutters for cutting a sheet of paper from the roll both
longitudinally and transversely to provide a full cut sheet that
has a leading edge and a trailing edge having dimensions adequate
to wrap the box; d) a user interface display having keys that
initiate measurement of the box and feeding of the roll by
dispensing only a first, partial section of the full cut sheet, the
user interface display having a key that must be pressed to
initiate feeding of a second section of the full cut sheet so that
the box can be partially, manually wrapped after the first partial
section is dispensed and before the second section is
dispensed.
26. The machine of claim 25 further including a plurality of rolls
of paper supported by the frame, and means for selecting a
particular roll for wrapping a particular box.
27. The machine of claim 25 in which the measuring section further
comprising multiple means for determining the length, width and
height of the box as it is being positioned.
28-36. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No.
10/256,468, filed Sep. 27, 2002, now U.S. Pat. No. 6,938,397, and
incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
REFERENCE TO A "MICROFICHE APPENDIX"
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to a method and apparatus for
wrapping articles such as boxes and more particularly to an
improved method and apparatus for semi-automatically wrapping boxes
of differing or random sizes in sequence, wherein the box to be
wrapped is automatically measured, its dimensions optionally
displayed on a user interface screen, and wherein a first section
of a full sheet of paper web is dispensed from a supply roll for
enabling an operator to partially wrap the box that was previously
measured, followed by a further dispensing of the sheet of paper
web to provide a second section of the full sheet, the cut full
sheet providing preselected dimensions that provides an optimum
size full cut sheet paper to wrap the package, while minimizing
waste.
[0006] 2. General Background of the Invention
[0007] There are numerous types of automated wrapping machines
which have been devised in the past. They are usually suited to a
particular purpose, and have their limitations when attempts are
made to apply them to other purposes.
[0008] For example, the typical wrapping machine found in the
supermarket for applying heat-seal film to packages of butchered
meat presents a clear face on the top for display of the meat and
hides all the gathered ends and spare film on the bottom of the
package. The machine works well in the supermarket for wrapping
butchered meat, but would not do an adequate job of wrapping
articles of random size, such as gifts in boxes.
[0009] Another class of machine is available for high speed
application of preprinted, precut wrappers to product, such as
candy bar wrappers to candy bars. While the finished package is
attractive and neatly wrapped, the product is usually of a single
size, and the wrappers are precut to accommodate that single
size.
[0010] Considering that the packages can be of any random size
within limits, the ability to meet that requirement is not straight
forward. If it is attempted to meet the requirement by using precut
sheets which are large enough to accommodate the largest box,
difficulty will be encountered in presenting a neat appearance in
the wrapped package for boxes which are smaller than the maximum
size.
[0011] A typical application for such machines is in gift wrapping.
In department stores that offer gift wrapping services, the
wrapping is usually done completely by hand. It is labor intensive,
sometimes incapable of keeping up with peak demands, and oftentimes
subject to variable quality of finished product. In hand wrapping,
whether the individual uses cut sheets or roll paper, the entire
operation of trimming the sheet to size, placing the box on the
sheet, folding the paper over the box and making the taped or glued
attachments is done by hand using sight and with the judgment of
the individual exercised at most steps of the process. Skill and
judgment are required to reliably produce attractively wrapped
packages on a regular basis.
[0012] Various patents have issued that are directly to automated
packaging and automatic gift wrapping machines. U.S. Pat. No.
5,535,573 discloses such an apparatus (blank unit) for feeding
blanks to an article which is to be wrapped.
[0013] The de Luca U.S. Pat. No. 5,651,237 discloses a method for
automatically feeding from a roll, successive pairs of inflatable
packaging bags each having a common intermediate inflation channel
to present the end bag upon a base platform for receiving an item
to be packaged, and then to fold the other bag of the pair
thereover to envelope the same; and then sealing the enveloping
bags to provide a package of appropriate item size, inflating the
bags through the inflation channel, and finally severing the
inflated package from the roll.
[0014] The Ginestra U.S. Pat. No. 5,655,356 (hereby incorporated
herein by reference)is entitled "Automatic Package Wrapping
Machine". That patent names Michael E. Miller (applicant herein) as
a co-inventor. The '356 patent discloses an automatic package
wrapping machine that wraps a box of arbitrary size. The box is
placed in the machine following which all operations are automatic.
As the box is immediately advanced to a ready-to-wrap position, its
length, width and height are automatically measured. Papers
withdrawn from a supply roll and automatically cut to a size
calculated to wrap the box. The paper is automatically applied to
wrap four sides of the box without causing the box to tilt or
tumble. The ends are then automatically wrapped by folding and
sealing of flaps, whereupon a neatly wrapped box is ejected from
the machine.
[0015] Another Ginestra and Miller patent is U.S. Pat. No.
5,671,593 (hereby incorporated herein by reference)entitled
"Semiautomatic Package Wrapping machine". In the Ginestra '593
patent, an automatic package wrapping machine wraps a box of
arbitrary size. The box is placed in the machine following which
all operations are automatic. As the box is automatically advanced
to a ready to wrap position, its length, width and height are
automatically measured. Paper is withdrawn from a roll supply and
automatically cut to a size calculated to wrap the box. The paper
is automatically applied to wrap four sides of the box without
causing the box to tilt or tumble. The ends have been automatically
processed by folding and sealing the flaps, whereupon a neatly
wrapped box is ejected from the machine.
[0016] The Tuyn et al. U.S. Pat. No. 6,050,057 discloses a
packaging apparatus for packaging mail items, magazines, books, CDs
and like products composed of one or more layers comprising a
product assembling path, a folding station, and a separating
station. The folding station comprising a first conveyor belt on
which at least a part of the packing material web is located which
extends below the products to be packed, a pulley element which is
arranged above the first conveyor belt and engages part of the
packing material web located on the top side of the products to be
packed, and connecting means by means of which the longitudinal
edges of the packing material web are interconnected, a pressure
plate which is arranged above the first conveyor belt, the top side
of which pressure plate is engaged by the pulling element, in
operation, with the interposition of at least the longitudinal
edges of the packing material web, the distance between the first
conveyor belt and the bottom side of the pressure plate being such
that the products of different thickness can pass there
between.
[0017] In the Adelman U.S. Pat. No. 6,115,999 there is disclosed a
gift wrap article forming method providing wrapping material which
is padded and waterproof.
[0018] The Newman U.S. Pat. No. 6,349,526 discloses an automated
packaging machine.
[0019] The Lay et al. U.S. Pat. No. 6,363,690 discloses an
automatic measuring device and method for dispensing materials.
BRIEF SUMMARY OF THE INVENTION
[0020] The present invention provides an improved semi-automatic
method and apparatus for wrapping a package such as a gift box. The
method includes the providing of an apparatus that can be in the
form of an enlarged frame or table having work surface areas that
can include a wrapping station and a measuring station.
[0021] One or more paper supply roll dispense paper to be used for
wrapping. Longitudinal and transverse cutters are provided for
trimming the paper. The longitudinal cutters trim the sides of the
paper web to provide a sheet for wrapping of desired width. The
transverse cutter cuts the web of paper to provide a desired length
to the sheet of paper to be used for wrapping.
[0022] At the measuring station, the package is placed against a
first set of stops at a fixed and known location that is spaced
away from the wrapping station. Stop bars index the package during
measurement and again during wrapping. Preferably three measuring
devices simultaneously contact the package and measure its length,
width, and height.
[0023] The package measurements are stored in a computer. They can
also optionally be displayed on a user interface screen. The screen
provides a keypad that can be used to initiate machine functions.
For example, a key is depressed when the package is to be measured.
Once measured, a first section of paper web is automatically
dispensed from the roll and cut longitudinally to provide a desired
width. The package is then placed on the first section of paper. A
keypad entry is made by the user so that an additional section of
paper web is dispensed, i.e. a second section that is also cut, but
both longitudinally and transversely. The second section of paper
web is cut to a desired width, and is also transversely cut to
define the overall length of the full cut sheet to be used in
wrapping.
[0024] When the first section of the paper web of wrapping paper is
dispensed, the package to be wrapped is manually placed on the
first section of paper web and partially, manually wrapped by an
operator.
[0025] When the second section is of paper web is dispensed, the
remaining portion of the package is manually wrapped.
[0026] This two step dispensing of the paper web enables an
operator to manually wrap a portion of the box, placing the cut
sheet leading edge at a seam. This seam can easily be matched with
the trailing edge of the wrapping paper when the second section of
wrapping paper has been dispensed and then cut transversely. In so
doing the package is encircled and wrapped with the cut sheet to
cover the box top, bottom, front and rear. The operator then
finishes the wrap by hand folding the end folds (i.e. sides of the
paper web) inwardly to cover the box or package ends.
[0027] In the method of the present invention, stops can optionally
be provided at the measuring station in the form of a pair of stop
bar members to define an index position during measuring. The
method can include placing the package in contact with both of the
stop members. A side and an end of the package that are ninety
degrees apart can each engage a stop member. This indexing to both
of the stop members ensures that an accurate measurement will be
made of every box or package, even when the boxes to be wrapped are
of random, unknown dimensions.
[0028] The box can be measured using a plurality of preferably
three mechanical measuring devices such as traveling pads. The pads
can move from an initial position spaced away from the box or
package to a position that contacts the box or package and then
returning to the initial position. Measurement of the length, width
and height of the box is complete when each pad has contact to the
box and moved away from it.
[0029] The method of the present invention can include a
preliminary step of applying adhesive material to the box prior to
the measuring step or prior to wrapping. Alternatively, no adhesive
can be applied to the box, wherein adhesive tape can be manually
applied to the wrapping paper as it is wrapped about the package or
box. It should be understood that other measuring devices can be
employed such as acoustic sensors, optical sensors or the like.
[0030] The semi-automatic random size over wrapping machine of the
present invention is based on the principle of automatic
measurement of a box or package by the push of an input and by that
input of measurement paper is dispensed off of a selected roll that
is cut to the exact width and length for that box.
[0031] The paper web is dispensed from the selected supply roll in
two stages. First the paper web is dispensed to a length that puts
a seam spot in a predesignated area on the package (e.g. at the
transverse centerline of the package or box top panel). The package
is placed against a stop, centered and ready for the operator to
fold and tape the dispensed first section of the paper web. With
another input the remainder of the paper is dispensed while the
operator pulls the box back against the backstop. The box or
package is ready for finishing, the over wrapping by the operator.
End folds are cut to the predescribed length and ready for operator
folding and taping. The whole process requires no manual trimming
and increases quality and productivity.
[0032] The present invention thus provides an improved
semiautomatic gift wrapping method and apparatus that increases
productivity as much as threefold compared to conventional manual
gift wrapping.
[0033] The present invention provides a method and apparatus that
precuts sheets that provide higher quality.
[0034] The apparatus of the present invention is easy to operate
and provides minimal waste.
[0035] The present invention provides an improved method and
apparatus that enables an operator to select a sheeter mode for
providing multiple sheets of the same size to multiple conventional
manual package wrapping stations for use in wrapping high volume
sizes such as, for example, shirt boxes and the like.
[0036] The present invention provides a method and apparatus for
wrapping gifts or packages that enables the user to easily size a
precut sheet with a desired seam locator, end flap length and
overlap.
[0037] The present invention provides a semiautomatic gift or
package wrapping station that enable packages of different sizes to
be wrapped including very small package sizes. A maximum package
size is determined by the paper width, but there is practically no
maximum as long as the paper roll is of sufficient length.
[0038] The present invention enables a package to be wrapped that
is very heavy, limited only by the maximum package weight that can
be handled safely by the operator.
[0039] The present invention provides an improved semiautomatic
gift or package wrapping station that can be in the form of a
single roll machine or an optional multi-roll machine wherein the
operator selects a particular roll such as for example one roll
from several rolls of different pattern wrapping paper.
[0040] The method of the present invention is semiautomatic,
enabling an operator to very quickly wrap a package. As part of the
method of the present invention, the package or box to be wrapped
is first placed in a corner of the measuring station, abutting two
provided stop bar members. The user then presses a "start" key on a
provided user interface display screen. The box is then measured,
and a first section of paper is dispensed from a selected supply
roll. This first section that is dispensed is cut only
longitudinally (and not transversely), to define the width of the
paper.
[0041] The user then places the box or package to be wrapped on the
first section of dispensed, cut paper sheet and against a ruled
stop at the wrapping station, preferably centering the package in
between the sides of the cut paper. A ruled gauge or other means
can be provided on the wrapping station stop to aid an operator in
centering the box on the wrapping paper section that has been
dispensed.
[0042] After the first section of the sheet of paper for wrapping
has been dispensed, the user manually wraps the paper around the
box or package and tapes the leading edge of the dispensed sheet
section to the top of the box. This operation can be done by
manually taping the leading edge to the box. Alternately,
double-sided tape or adhesive can be applied to the box before it
is measured (or shortly thereafter). Any other adhesive could be
employed at this manual step.
[0043] An additional key that is provided on the user interface
display is a "continue" key that , when depressed, causes a second
section of the sheet of paper to be dispensed. When the "continue"
key is pressed, the user then manually pulls the box away from the
wrapping section stop as the paper advances. The second section of
paper is then cut both longitudinally and transversely. The
transverse cut is made at the trailing edge of the sheet of paper
to be used in wrapping.
[0044] The operator then manually completes the over wrap by
folding the trailing edge of the cut sheet up to meet the leading
edge and then folds and tapes the enfolds manually to complete the
wrap.
[0045] An optional feature of the present invention is a "sheeter"
feature. The sheeter feature is used when an operator wants to cut
and dispense multiple sheets of paper of the same size such as for
example to wrap a number of boxes of the same size and shape at a
different work station.
[0046] To operate the sheeter function, the "sheeter mode" key on
the user interface display panel is pressed. The box is then placed
on the measuring station and measured. The operator selects the
quantity of sheets to be dispensed and cut. The box is measured and
each of the sheets is automatically cut to size. This enables a
user at another (conventional manual) work station to obtain for
example a selected number of sheets of paper to wrap several boxes
of the same size, such as shirt boxes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] For a further understanding of the nature, objects, and
advantages of the present invention, reference should be had to the
following detailed description, read in conjunction with the
following drawings, wherein like reference numerals denote like
elements and wherein:
[0048] FIG. 1 is a perspective view of the preferred embodiment of
the apparatus of the present invention;
[0049] FIG. 2 is a partial perspective view of the preferred
embodiment of the apparatus of the present invention illustrating
the paper feed and cutting mechanism;
[0050] FIG. 3 is a sectional view of the preferred embodiment of
the apparatus of the present invention taken along the lines 3-3 of
FIG. 2;
[0051] FIGS. 4-12 are fragmentary views of the preferred embodiment
of the apparatus of the present invention and illustrating the
method of the present invention;
[0052] FIG. 13 is a fragmentary side view of the preferred
embodiment of the apparatus of the present invention;
[0053] FIG. 14 is a fragmentary view of the preferred embodiment of
the apparatus of the present invention;
[0054] FIG. 15 is a view of the user interface display panel
portion of the preferred embodiment of the apparatus of the present
invention;
[0055] FIG. 16 is a block diagram illustrating machine control for
the semi-automatic wrapping apparatus of the present invention;
and
[0056] FIG. 17 is a flow chart illustrating a sequence of steps for
the control system of FIG. 16.
DETAILED DESCRIPTION OF THE INVENTION
[0057] FIG. 1 shows generally the preferred embodiment of the
apparatus of the present invention designated generally by the
numeral 10. Gift wrapping apparatus 10 includes a structural frame
11 that can be of welded steel or the like. Frame 11 is comprised
generally of a front frame section 11A and a rear frame section
11B. The frame 11 can be comprised of a plurality of vertical
members that can include legs 12 and a plurality of transverse or
horizontal supports 13.
[0058] Frame 11 is provided with a measuring station 14, wrapping
station 16, paper supply 23, and a paper feed and cutting mechanism
24. At measuring station 14, a pair of stop bar members 18, 19 are
provided along two edges of measuring station 14 work surface 15 as
shown in FIG. 1. The stop bar members 18, 19 preferably define an
angle of 90 degrees. When a package 20 is to be wrapped, it is
first placed on work surface 15 of measuring station 14. A side and
an end of the box of package 20 are placed respectively against
stop bar members 18, 19. Home key 70 of user interface display 21
is depressed to initialize the system. The start key 27 of user
interface 21 is then depressed. The package 20 is then measured.
There are three measuring devices oriented along orthogonal axes as
shown in FIGS. 1 and 4-5. Each measuring device is comprised of a
programmable intelligent motor 28 that rotates a threaded shaft 88
that engages a pad 29. The motors 28 for each measuring device
rotate their shaft 88 until the pad moves from an initial position
to engage the package to be measured before returning to the
original position. The measurement devices are commanded by
computer to drive pads 29 into the box 20 until each of their
respective motor 28 switches are actuated. Then the motors 28 stop
and reverse the direction of shafts 88, returning pads 29 back to
their initial, home position and the box 20 dimension is captured
via switch input to the motor 28. The input of the switch signals
each motor 28 in its internal program to send via serial lines the
encoder counts traveled up until the switch was made. The computer
in its program uses these counts to compute the length, height and
width of the box 20 for all subsequent operations.
[0059] User interface display screen 21 is provided that has a
number of windows for displaying values such as dimensions of the
box that is measured and a number of other windows that are in the
form of keypad keys for inputting in information "start",
"continue" (key 74), "sheeter" (key 75), paper select (key 76),
paper supply roll number (keys 77-82), and the selected roll number
display (key 83). Other machine functions can include a number of
boxes wrapped indicator (key 84), clear key 85, time of last box
display 86 and average time display 87.
[0060] A superstructure 22 supports paper supply 23 and its paper
web and feed rollers (see FIGS. 13-14) in a fashion that enables
any selected roll of paper 26 to be used in a wrapping operation.
Alternatively, the apparatus can be a single roll machine.
[0061] Each supply roll 26 thus provides a paper web 25 that can be
advanced from the selected supply roll 26 and fed to a paper feed
and cutting mechanism designated generally by the numeral 24 in
FIG. 1. At this paper feed and cutting mechanism 24, the paper web
is fed from the supply roll 26 that is selected toward the work
surface 17 of wrapping station 16 and simultaneously trimmed if
necessary to provide a desired width. The "width" is automatically
set by spacing two rotary knives or other like cutting devices, a
selected distance apart immediately before the paper web 25 is fed
through the paper feed and cutting mechanism 24 toward work surface
17 of wrapping station 16.
[0062] As part of the method of the present invention (see FIGS.
4-12), the paper web 25 is then automatically fed until a sheet of
paper for wrapping of desired width and length has been dispensed
and cut. This feeding operation is accomplished in two steps. A
first section 92 of the web 25 of paper on the selected roll 26 is
fed and simultaneously trimmed to a selected width (see FIGS. 3 and
6). Before the second section 93 of web 25 is fed, a user places
box 20 on web 25 (see FIG. 7), manually over wraps part of the
package or box to be wrapped with the first section and ensures
that it is adhered to the package or box using tape (see FIG. 8),
adhesive, preapplied double-sided tape strips 91 or the like. The
user then uses continue key 72 of interface display 21 to key in a
continuation of the process so that the second section 93 of the
web is fed (see FIG. 9). At this time, the user pulls box 20 to
backstop 33 as the second section 93 of paper web 25 is dispensed.
This second section 93 is cut longitudinally with cutters 42, 43 to
the selected width, but also transversely to determine the overall
length of the cut sheet to be used for wrapping and to provide
trailing edge 96. At this point the user can then wrap the
remainder of the box by over wrapping the box with a transversely
cut trailing edge 96 of the full cut sheet of paper 94 (see FIG.
10) and then folding the ends in a traditional manner (see FIGS.
11, 12). The ends of the package or box can be then taped or simply
adhered to adhesive or double-sided tape strips 91 that had been
applied before or just after the measuring step.
[0063] FIGS. 2-3 show paper feed and cutting mechanism 24 in more
detail. A pair of rails 37, 38 are attached to FIG. 11 at support
plates 35, 36. Threaded shaft 39 is positioned generally in between
and parallel to rails 37, 38 as shown in FIG. 2. Threaded shaft 39
is driven by motor 40 and belt 41. Left 42 and right 43
longitudinal rotary cutters are provided with internally threaded
nuts 46, 47 that engage the threads of shaft 39 so that when the
motor 40 rotates shaft 39 in one direction, the cutters 42, 43
slide upon rails 37, 38 and move apart. When motor 40 rotates shaft
40 in an opposite rotational direction, cutters 42, 43 move
together. The threads on shaft sections 39A, 39B are thus helical
threads that spiral in opposite directions. In between sections
39A, 39B is support 44 having bushing 45 that rotatably supports
shaft 39. Support 44 is affixed to rails 37, 38.
[0064] In FIG. 3, a single longitudinal cutter 43 is shown in more
detail. However, the construction left longitudinal cutter 42 can
be substantially the same as that shown for right longitudinal
cutter 43 of FIG. 3. Cutter 43 can include housing 44 that slides
upon rails 37, 38. Internally threaded nut 47 engages externally
threaded shaft 39 at section 39B. Rotary cutter wheel 48 rotatably
attaches at central shaft 49 to housing 44. Wheel 48 has cutting
edge 50. Edge 50 engages roller 51 when cutting so that when web 25
passes between edge 50 and roller 51 it is cut, trimming the sides
of web 25 to provide a desired overall width. Roller 51 is driven
by shaft 52 that engages belt 53 driven by motor 54. The cutter
shells 48 of both cutters 42, 43 engage roller 51.
[0065] When the paper web 25 is to be trimmed to a final width that
is narrower than the width of the web 25 as contained on a selected
supply roll 26, cutters 42, 43 are moved with motor 40 to a correct
spacing. A first section 92 of the paper web 25 is then advanced as
indicated by arrow 25 in FIG. 3. Each cutter 42, 43 cutter wheel 48
cuts the paper web 25. The waste that is trimmed from the sides of
paper web 25 is directed downwardly as indicated by arrow 56 in
FIG. 3 as waste strip 57. Endless belt 58 mounted on idler rollers
59A, 59B, 59C ensures that waste strip 57 moves down in the
direction of arrow 56. Feed rollers 97, 98 feed paper web 25 to
work surface 17. Rollers 97, 98 can be driven by motor 54 or can be
driven by their own motor or motors.
[0066] In addition to the longitudinal cutters 42, 43 there is
provided a transverse cutter 60. The transverse cutter 60 cuts the
paper web 25 after the paper web is advanced twice in sequence with
a pause in between (see FIGS. 7-9) for enabling an operator or user
to manually wrap part of package 21. Transverse cutter 60 includes
a carriage or housing 63 slidably mounted upon rails 61, 62. Rails
61, 62 are firmly anchored to frame 11 rear section 11B. Rotary
blade 64 having cutting edge 65 is rotatably mounted upon carriage
63. Motor drive 66 drives endless belt 69 with drive roller 68.
Belt 69 can be supported with guide rollers as needed such as
roller 67, and one or more guide rollers (not shown) that support
the part of belt 69 that is spaced away from motor 66. In order to
cut web 25 and provide the trailing edge to a full cut sheet of
desired size, cutter wheel 64 travels back and forth upon rails 61,
62 as indicated by arrow 70 in FIG. 2.
[0067] FIG. 16 is a flow chart illustrating the primary elements of
a controller capable of operating the apparatus 10 of the present
invention of FIG. 1. The controller is based upon a conventional
CPU motherboard 120. Internal to the computer 120 is a standard
memory 121 which can consist of a combination of random access
memory, ROM and/or disk memory 122, 123 which contains the program
to achieve the functionality described herein. The conventional
microprocessor 120 can optionally be equipped with modem 124,
network 125, keyboard 126.
[0068] User or operator interface display 21 (see FIGS. 1 and 15)
can interface with microprocessor 120 using graphics card 127 and
serial port 128.
[0069] The Microprocessor 120 interfaces to the apparatus 10
through the serial line 133 that connects to the intelligent
motors, example being 28. The serial line 133 passes all
information to the intelligent motors, 28 and others, from the
microprocessor 120 and controls such aspects as velocity,
acceleration, position through encoder counts and other variables
as required. Inputs 129 are generally directed through the motors
which process the input in the appropriate manner as commanded.
Outputs 130 are generally directed from the motors, 28 and others,
based on specific motor programming and control a relay 131 which
in turn, turns on and off devices such as solenoid valves.
[0070] One of the outputs produced by the microprocessor for
driving the package wrapping machine 10 is the serial communication
to the numerous intelligent drive motors. The serial line daisy
chains between all motors, each of which has its own address and is
connected to the microprocessor 120. Alternative control schemes
could be utilized and include different communication links between
the motors. Additionally the motor system could be constructed
utilizing conventional servo motors, stepping motors, dc motors,
air cylinders and combinations of all used and suggested. These
motors could require separate drives and motion controllers which
also could be separate or in combination. In either case a
microprocessor of some type would control the apparatus 10 in some
manner. This microprocessor could be constructed as an embedded
controller or perhaps a PLC.
[0071] FIG. 17 represents a program of operation by which the
processor system of FIG. 16 operates to control the package
wrapping machine of FIGS. 1-14. The blocks of FIG. 17 are described
in terms of their functionality in connection with the
semi-automatic package wrapping machine 10 of the present
invention. The process starts 100 at which point an operator or
user applies power to the apparatus 10. Power application boots up
computer, powers up the motors, and resend programming information
to the motors via serial line.
[0072] Setup 101 is a function accessible from the operator
interface display 21 that allows the operator to change certain
parameters and additionally allows maintenance and service
personnel to adjust certain offset numbers if so necessary. Many of
the initial machine start up variables are carried here and can be
modified for any reason. These items that can be changed include
but are not limited to such variables as motor speed, acceleration,
offsets, number of roll positions.
[0073] Pushing the Home Button 102 on the operator interface sends
variables to the motors which select the appropriate homing program
in each motor. Motor drives to home position against a hard stop in
torque mode. It senses the rise in torque and stops and backs off
the home stop a variable amount and sets zero to the motor encoder.
Subsequent moves reference the zero set point.
[0074] The machine may be equipped with one or more supply rolls of
paper 26. If only equipped with one roll 26, this function does not
apply and roll loading and prep is a manual function. If the
machine 10 is so equipped with more than one roll 26, then the
operator interface display 21 provides that number of roll
selections (see keys 76-83 of user interface display 21). A prep
button is provided and after the roll number is selected the prep
button would be pushed for prepping. The select button is then
pushed to start the required move. The roll elevator upon command
then positions the roll position selected to a distance above the
normal feed in point that is convenient for the operator to thread
the paper web 25 and cut it off square against a feed out guide.
When a selection is made the paper feed engagement assembly 134 is
released via an air valve and the roll elevator motor moves the
number of encoder pulses and direction sent to the motor 135 over
the serial port 132 and line 133 for that troll position from its
current position. Once the roll elevator halts motion the paper
feed engagement assembly is preengaged.
[0075] A new roll 26 can be loaded at this point 104 and prepping
can occur for that roll. For each box in a multi-roll machine, the
option can be made at this point 105 for the operator to select the
paper roll for that box 20. Selection is made via the operator
interface display 21. The operator selects the roll position to run
(see keys 77-82) and pushes the select button (see key 76). The
elevator motor 136 is then sent via the serial port 132 and serial
line 133 the number of encoder pulses to move from its current
location and additionally the motor rotational direction. The paper
feed engagement assembly 134 disengages before movement and
renegades after the movement is complete (see FIG. 13). Air
cylinder 139 moves assembly 134 housing 140 to rotate about pivot
141 as indicated schematically by arrow 142 in FIG. 13. Gear 143 is
driven by motor 135. Gear 143 engages the selected gear 144 of a
feed roller and its companion roller 146. When housing 140 is
rotated to engage pinion 137 with gear 144, a pair of rollers 145,
146 can pull paper web from a particular, selected supply roll 26.
There are thus a pair of rollers 145, 146 for each supply roll
26.
[0076] For measurement of the box 106 to take place the operator
must push the box into the corner of the measurement area. This is
a manual function by the operator.
[0077] The Sheeter Function 107 allows the operator to select the
number of sheets desired for a box size and the machine will output
that number of precut sheets for that box. The first step is to
enter the number of sheets required on the keypad of the operator
interface.
[0078] Pushing Sheeter key 75 on the operator interface display 21
once a box is placed in the measurement corner actuates the Sheeter
Function (operation 108). When the sheeter function (key 75) is
pushed by the operator the measurement axis are commanded by
computer to drive into the box until each of their respective
switches are actuated. Then the motors stop and reverse back to
their initial, home position and the box dimension is captured via
switch input to the motor. The input of the switch signals the
motor in its internal program to send via serial lines the encoder
counts traveled up until the switch was made. The computer in its
program uses these counts to compute the length, height and width
of the box for all subsequent operations. It is after the
measurement is calculated that the cutter motor is commanded to
drive the cutters to a location that meets the requirements of the
computer program for sheet width for the particular box.
Additionally, the elevator paper feed motor and the main paper feed
motor start and are directed to move a distance calculated by
computer. Once the distance is met the cutter motor 60 is commanded
by the computer program to cut the paper, which is already at its
proper length for that box 20. This process continues until the
last sheet is dispensed. At that point the elevator paper feed
motor reverses and drives the paper that is at the knife position
back to the elevator entrance position. At 109, the operator
collects the sheets as they are dispensed from the machine. This is
a manual operation.
[0079] At 110, pushing start key 27 on the operator interface
display 21, once a box is placed in the measurement corner actuates
the Start Function. When the Start function is pushed by the
operator, the three measurement pads 29 are commanded by computer
120 to drive into the box 20 until each of their respective
switches are actuated. Then the motors stop and reverse back to
their home position and the box dimension is captured via switch
input to the motor. The input of the switch signals the motor in
its internal program to send via serial lines the encoder counts
traveled up until the switch was made. The computer in its program
uses these counts to compute the length, height and width of the
box for all subsequent operations. It is after the measurement is
calculated that the cutter motor 40 is commanded to drive the
cutters 42, 43 to a location that meets the requirements of the
computer program for sheet width for the particular box 20. The
cutters and scrap belts are air loaded and when the cutters 42, 43
are commanded to move, the air pressure is removed from the devices
and when the cutters reach destination the air pressure is
commanded back on via outputs from the intelligent motors.
[0080] The elevator paper feed motor and the main paper feed motor
start in unison when the cutters 42, 43 have nearly met their
destination and are directed to move a distance calculated by
computer. This distance is either the amount of paper (first paper
web section 92) required to wrap around the box 20 to the seam spot
99 plus offset or the amount of paper required to satisfy the
entire required length. If the former, then once that amount of
paper 25 is dispensed the computer awaits an operator input to
continue. If the latter, the cutter motor 66 is commanded by the
computer program to cut the paper web 25 if the paper fed out is
already at its proper length for that box 20. At that point the
elevator paper feed motor reverses and drives the paper that is at
the knife position back to the elevator entrance position in order
a paper change does not damage the paper end. Once the paper is cut
by the cutter 60, the main paper feed motor only advances the paper
to the point where, when wrapped around the box 20, it would just
overlap the seam spot 99 by the offset entered initially.
[0081] At the point in the last operation where the measurement
devices have functioned it would be possible to apply adhesive
transfer tape to the top and sides of the box for speedy manual
paper adherence. Step 111 is an option for other taping methods or
in fact could be done before the box is measured. This function is
completely at the customer's option.
[0082] Once function 110 has completed, the operator repositions
the box 20 that is still in the measurement corner over the
dispensed paper up against the ruled box stop bar 31 on the machine
frame 11. The operator additionally centers the box via zero
centerline scale, operator display and scale or estimation,
indicated as operation 112.
[0083] At 113, the operator manually pulls the paper tight over the
box 20 while the box 20 is being held up against the box stop 31 of
the machine frame 31. If the box 20 is prepared (as mentioned in
item 111) above the operator adheres the leading edge 95 to the
tape tightly. Other options at this point could be such methods as
applying scotch tape or simply not taping at all and holding the
edge of paper in place by hand for the next step.
[0084] Optionally at this point 114 the operator can apply adhesive
transfer tape to the leading edge setting up the final adherence in
the next step. Other options include doing nothing.
[0085] At this point 115 the operator selects the continue button
on the operator interface display 21. This signals the paper feed
motors or motor to advance the remainder of the paper (second
section 93) or the length of paper to satisfy the overall length
for the cut by transverse cutter 60. In either case the operator
pulls back on the box 20 by hand while the paper 25 is feeding out.
The operator pulls until the back edge of the box hits against the
back box stop 33 on the worktable 17. The remainder of the paper is
fed out at this point or somewhere during the pull back or after
the paper stops feeding, the transverse shear knife 60 is actuated,
paper 25 is cut to length and then the main paper feed motor
dispenses the entire amount of paper out onto the work table 17.
After final dispersal of paper (full cut sheet 94) the shear knife
returns to its home position and the elevator paper feed motor is
commanded to reverse to pull back the amount of paper in the
machine that is up to the knife 60.
[0086] As described in item 115 above the operator pulls back on
the paper keeping it tight while it being fed out of the machine.
At 116, the operator pulls both paper web 25 and box 20 until the
back of the box hits the backstop on the work table work surface
17.
[0087] At this point 117 the operator may pull the end of paper
that just exited the machine 10 over the box 20 and adhere to the
box 20 after pulling tightly. If the adhesive was not applied prior
as described in item 114 he or she may tape it down in any other
manner deemed necessary by the customer. Box 20 is now overwrapped
(see FIGS. 10-11). At this point the operator may pass it to
another operator for final manual enfolding or do that process
himself (see FIGS. 11-12).
[0088] For operation 118, end folds, which are cut to a
predetermined length by computer calculation, do not require
additional trimming and fold in easily (see FIG. 12). If the box
had adhesive strips 91 preapplied to the ends then the operator
simply folds them in and pulls down the top flap over the
preapplied adhesive. Next using any adhesive method the operator
folds up the bottom flap and adheres. The operator repeats this
process on the other end. Box 20 is completely wrapped ready for
subsequent operations.
[0089] The apparatus 10 of the present invention could be set in a
"repeat" mode. Thereby when hitting a provided repeat button on
operator interface display 21, the machine 10 will simply deliver
the same full cut sheet of paper 94 that was last cut from the
prior measurement every time the start button is pushed. Therefore
if there is a stack of 6 boxes, all of the same size, only the
first one needs to be measured or have manual input of measurement.
The repeat button could for example flash on and off until hit
again to cancel the repeat function. This "repeat" function differs
from the sheeter mode in that it optionally allows for wrapping
each box utilizing the standard process.
[0090] The following is a list of suitable parts and materials for
the various elements of the preferred embodiment of the present
invention.
PARTS LIST
[0091] Part Number Description [0092] 10 gift wrapping apparatus
[0093] 11 frame [0094] 11A front section [0095] 11B rear section
[0096] 12 leg [0097] 13 horizontal support [0098] 14 measuring
station [0099] 15 work surface [0100] 16 wrapping station [0101] 17
work surface [0102] 18 stop bar [0103] 19 stop bar [0104] 20
package [0105] 21 user interface display [0106] 22 superstructure
[0107] 23 paper supply [0108] 24 paper feed and cutting mechanism
[0109] 25 paper web [0110] 26 supply roll [0111] 27 start key
[0112] 28 intelligent motor [0113] 29 measuring pad [0114] 30
elongated housing [0115] 31 ruled box stop bar [0116] 32 indicia
[0117] 33 backstop [0118] 34 motor drive [0119] 35 support plate
[0120] 36 support plate [0121] 37 upper rail [0122] 38 lower rail
[0123] 39 externally threaded shaft [0124] 39A shaft section [0125]
39B shaft section [0126] 40 motor [0127] 41 belt [0128] 42 left
longitudinal cutter [0129] 43 right longitudinal cutter [0130] 44
support [0131] 45 bushing [0132] 46 nut [0133] 47 nut [0134] 48
cutter wheel [0135] 49 shaft [0136] 50 cutting edge [0137] 51
roller [0138] 52 shaft [0139] 53 belt [0140] 54 motor [0141] 55
arrow [0142] 56 arrow [0143] 57 waste strip [0144] 58 belt [0145]
59A roller [0146] 59B roller [0147] 59C roller [0148] 60 transverse
cutter assembly [0149] 61 upper rail [0150] 62 lower rail [0151] 63
carriage [0152] 64 blade [0153] 65 cutting edge [0154] 66 motor
drive [0155] 67 roller [0156] 68 drive roller [0157] 69 endless
belt [0158] 70 home key [0159] 71 length display [0160] 72 width
display [0161] 73 height display [0162] 74 continue key [0163] 75
sheeter mode key [0164] 76 roll supply select key [0165] 77 roll
number key [0166] 78 roll number key [0167] 79 roll number key
[0168] 80 roll number key [0169] 81 roll number key [0170] 82 roll
number key [0171] 83 paper supply number display [0172] 84 number
of boxes display [0173] 85 clear key [0174] 86 time last box
display [0175] 87 average time display [0176] 88 threaded shaft
[0177] 89 setup key [0178] 90 stop key [0179] 91 adhesive strip
[0180] 92 first page web portion [0181] 93 second page web portion
[0182] 94 full cut sheet [0183] 95 leading edge [0184] 96 trailing
edge [0185] 97 feed roller [0186] 98 feed roller [0187] 99 seam
[0188] 100 power on step [0189] 101 setup step [0190] 102 select
home step [0191] 103 select paper step [0192] 104 roll prep step
[0193] 105 select paper roll step [0194] 106 insert box measure
step [0195] 107 select sheets step [0196] 108 select sheeter
function step [0197] 109 collect sheet step [0198] 110 start step
[0199] 111 tape option step [0200] 112 centering step [0201] 113
first overwrap step [0202] 114 optional taping step [0203] 115
continue step [0204] 116 second section paper step [0205] 117
second overwrap step [0206] 118 end fold step [0207] 119 roll
elevator [0208] 120 CPU motherboard [0209] 121 memory [0210] 122
hard disc [0211] 123 optional floppy disc [0212] 124 optional modem
[0213] 125 optional network [0214] 126 optional keyboard [0215] 127
graphics card [0216] 128 serial port [0217] 129 input [0218] 130
output [0219] 131 relay [0220] 132 serial port [0221] 133 serial
line [0222] 134 paper feed engagement assembly [0223] 135 paper
feed motor [0224] 136 elevator motor [0225] 137 pinion gear [0226]
138 rack [0227] 139 air cylinder [0228] 140 housing [0229] 141
pivot [0230] 142 arrow [0231] 143 gear [0232] 144 gear [0233] 145
feed roller [0234] 146 feed roller
[0235] The foregoing embodiments are presented by way of example
only; the scope of the present invention is to be limited only by
the following claims.
* * * * *