U.S. patent application number 13/602347 was filed with the patent office on 2013-03-14 for multiple robot system.
The applicant listed for this patent is Thomas ANDERSON, Michael BRUZIK, Shawn GREEN, Timothy HILLESHEIM, Michael KLEAR, Thomas MUTCH, Daniel SCHMIDT. Invention is credited to Thomas ANDERSON, Michael BRUZIK, Shawn GREEN, Timothy HILLESHEIM, Michael KLEAR, Thomas MUTCH, Daniel SCHMIDT.
Application Number | 20130061558 13/602347 |
Document ID | / |
Family ID | 47828592 |
Filed Date | 2013-03-14 |
United States Patent
Application |
20130061558 |
Kind Code |
A1 |
KLEAR; Michael ; et
al. |
March 14, 2013 |
MULTIPLE ROBOT SYSTEM
Abstract
The present invention relates generally to film wrapping or
packaging systems, and more particularly to a new and improved
robotic film wrapping or packaging system which is not only
substantially entirely automatic in its operation except for its
initialization or START procedure, but in addition, a single
programmable logic controller (PLC) can control the cyclic
operations of one or more film wrapping or packaging robots.
Inventors: |
KLEAR; Michael; (Chicago,
IL) ; SCHMIDT; Daniel; (Arlington Heights, IL)
; BRUZIK; Michael; (Alexandria, MN) ; HILLESHEIM;
Timothy; (West Union, MN) ; GREEN; Shawn;
(Alexandria, MN) ; ANDERSON; Thomas; (Alexandria,
MN) ; MUTCH; Thomas; (Le Sueur, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KLEAR; Michael
SCHMIDT; Daniel
BRUZIK; Michael
HILLESHEIM; Timothy
GREEN; Shawn
ANDERSON; Thomas
MUTCH; Thomas |
Chicago
Arlington Heights
Alexandria
West Union
Alexandria
Alexandria
Le Sueur |
IL
IL
MN
MN
MN
MN
MN |
US
US
US
US
US
US
US |
|
|
Family ID: |
47828592 |
Appl. No.: |
13/602347 |
Filed: |
September 4, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61573140 |
Sep 12, 2011 |
|
|
|
61687575 |
Apr 27, 2012 |
|
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Current U.S.
Class: |
53/218 |
Current CPC
Class: |
B65B 51/06 20130101;
B65B 11/025 20130101 |
Class at
Publication: |
53/218 |
International
Class: |
B65B 11/02 20060101
B65B011/02 |
Claims
1. A robot system for wrapping or packaging at least one palletized
load, disposed at at least one film wrapping or packaging station,
within wrapping or packaging film, comprising: at least one robot,
having a reel of wrapping or packaging film mounted thereon,
wherein said at least one robot is respectively disposed adjacent
to the at least one palletized load, disposed at the at least one
film wrapping or packaging station, so as to respectively wrap or
package the at least one palletized load within wrapping or
packaging film; and an adhesive member applicator assembly, mounted
upon said at least one robot, for applying at least one adhesive
member to the at least one palletized load such that a leading end
portion of said wrapping or packaging film can be adhered to the at
least one palletized load whereby the at least one palletized load
can be automatically wrapped or packaged, within the wrapping or
packaging film, during a wrapping or packaging operation without
requiring the services of an operator.
2. The system as set forth in claim 1, further comprising: a
programmable logic controller (PLC) operatively connected to said
at least one robot, and in communication with said at least one
robot, so as to control said at least one robot in order to cause
said at least one robot to perform a film wrapping or packaging
operation upon the at least one palletized load.
3. The system as set forth in claim 2, wherein: said programmable
logic controller (PLC) automatically controls said at least one
robot such that said at least one robot commences a film wrapping
or packaging operation at a predetermined HOME position, and upon
conclusion of said film wrapping or packaging operation, said
programmable logic controller (PLC) causes said at least one robot
to automatically return to said HOME position.
4. The system as set forth in claim 1, wherein: said at least one
robot comprises a multiple number of robots respectively disposed
adjacent to a multiple number of palletized loads disposed at a
multiple number of packaging or wrapping stations; wherein each one
of said multiple number of robots has an adhesive member applicator
assembly disposed thereon for respectively applying a leading end
portion of a wrapping or packaging film onto a respective one of
the multiple number of palletized loads.
5. The system as set forth in claim 4, further comprising: a single
programmable logic controller (PLC) operatively connected to all of
said multiple number of robots, and in communication with all of
said multiple number of robots, so as to control all of said
multiple number of robots in order to cause said multiple number of
robots to perform film wrapping or packaging operations upon their
respective palletized loads.
6. The system as set forth in claim 5, wherein: said single
programmable logic controller (PLC) controls each one of said
multiple number of robots automatically such that each one of said
multiple number of robots commences a film wrapping or packaging
operation at a predetermined HOME position, and upon conclusion of
said film wrapping or packaging operation, said programmable logic
controller (PLC) causes each one of said multiple number of robots
to automatically return to said HOME position.
7. The system as set forth in claim 1, wherein: said at least one
robot has a forward steering wheel assembly disposed thereon so as
to permit said at least one robot to maintain a substantially
circular locus path around the at least one palletized load during
a film wrapping or packaging operation.
8. The system as set forth in claim 4, wherein: each one of said
multiple number of robots has a forward steering wheel assembly
disposed thereon so as to permit each one of said multiple number
of robots to maintain its substantially circular locus path around
each one of the multiple number of palletized loads during a film
wrapping or packaging operation.
9. The system as set forth in claim 7, wherein: said substantially
circular locus is defined around ther at least one film wrapping or
packaging station and comprises a member, selected from the group
comprising a magnetic strip and a particularized paint, which can
be sensed by said at least one robots as said at least one robot
traverses said substantially circular locus.
10. The system as set forth in claim 8, wherein: said substantially
circular locus is defined around each one of the multiple number of
film wrapping or packaging stations and comprises a member,
selected from the group comprising a magnetic strip and a
particularized paint, which can be sensed by each one of said
multiple number of robots as each one of said multiple number of
robots traverses said substantially circular locus.
11. The system as set forth in claim 1, wherein: said adhesive
member may be selected from the group comprising an adhesive dot,
an adhesive patch, an adhesive strip, an adhesive tape, and an
adhesive label.
12. The system as set forth in claim 1, wherein: said adhesive
member applicator assembly comprises a supply roll of tape having a
plurality of adhesive members disposed upon said tape, an
applicator roller around which said tape is disposed such that said
tape, having said plurality of adhesive members disposed thereon,
can be disposed in contact with the palletized load, and a take-up
reel for taking up portions of said tape from which said plurality
of adhesive members have been removed and applied to the palletized
load.
13. The system as set forth in claim 12, further comprising: an
actuator for moving said applicator roller into contact with the
palletized load such that at least one of said plurality of
adhesive members, from said supply roll of tape, can be applied to
the palletized load in order to permit said leading end of said
wrapping or packaging film to be adhered to the palletized load
when a film wrapping or packaging operation is to be commenced.
14. The system as set forth in claim 13, further comprising: a
cutting implement for severing the packaging or wrapping film upon
the completion of a palletized load packaging or wrapping operation
whereby a trailing end portion of the packaging or wrapping film
will be formed so as to self-adhere to the packaged or wrapped
palletized load while a leading end portion of the packaging or
wrapping film is also formed in preparation for the commencement of
a new packaging or wrapping operation; and a clamping member
fixedly connected to said cutting implement for clamping the
leading end portion of the packaging or wrapping film in
preparation for the commencement of a new packaging or wrapping
operation.
15. The system as set forth in claim 14, further comprising: a
first actuator operatively connected to said clamping member and
said cutting implement for angularly moving said clamping member
and said cutting implement to a first position at which said
clamping member and said cutting implement can move across the
boundary of the packaging or wrapping film leading from the
palletized load to said robot, and a second position at which said
clamping member and said cutting implement can engage the packaging
or wrapping film leading from the palletized load to said robot
such that said cutting implement can sever the packaging or
wrapping film and thereby form the trailing and leading end
portions of the packaging or wrapping film while said clamping
member can clamp the leading end portion of the packaging or
wrapping film in preparation for the commencement of a new
packaging or wrapping operation.
16. The system as set forth in claim 15, further comprising: a
second actuator operatively connected to said clamping member and
said cutting implement for moving said cutting implement and said
clamping member toward and away from the packaging or wrapping film
such that when said cutting implement and said clamping member are
moved toward the packaging or wrapping film, said cutting implement
severs the packaging or wrapping film thereby forming the trailing
and leading end portions of the packaging or wrapping film and said
clamping member clamps the leading end portion of the packaging or
wrapping film, while when said cutting implement and said clamping
member are moved away from the packaging or wrapping film, the
leading end portion of the packaging or wrapping film is able to be
released.
17. The system as set forth in claim 16, further comprising: an
application pad, across which the leading end portion of the
packaging or wrapping film is disposed; and a third actuator for
moving said application pad into engagement with the palletized
load such that the leading end portion of the packaging or wrapping
film can be applied to the adhesive tape affixed to the palletized
load.
18. The system as set forth in claim 15, further comprising: a
roller wheel rotatably mounted upon said clamping member for
permitting said clamping member to be rotatably moved between said
second and first positions so as not to snag the leading end
portion of the packaging or wrapping film when the leading end
portion of the packaging or wrapping film is to be released from
its clamped state after the leading end portion of the packaging or
wrapping film has been applied to the palletized load.
19. The system as set forth in claim 4, further comprising: a metal
plate disposed upon a floor region adjacent to each one of the
multiple number of film wrapping or packaging stations; and a
proximity sensor disposed upon each one of said multiple number of
robots so as to detect said metal plate and thereby ensure that
each one of said multiple number of robots returns to its HOME
position at the completion of a packaging or wrapping
operation.
20. The system as set forth in claim 1, further comprising: a
proximity counter disposed upon said at least one robot for
determining the amount of wrapping or packaging film applied to the
at least one palletized load.
Description
CROSS REFERENCE TO RELATED PATENT APPLICATION
[0001] This patent application is related to, based upon, and
effectively a utility/non-provisional patent application conversion
from U.S. Provisional Patent Application Ser. No. 61/573,140, which
was filed on Sep. 12, 2011, the filing date benefits of which are
hereby claimed, and U.S. Provisional Patent Application Ser. No.
61/687,575 which was filed on Apr. 27, 2012, the filing date
benefits of which are also hereby claimed.
FIELD OF THE INVENTION
[0002] The present invention relates generally to film wrapping or
packaging systems, and more particularly to a new and improved
robotic film wrapping or packaging system which is not only
substantially entirely automatic in its operation, except for its
initialization or START procedure, but in addition, a single
programmable logic controller (PLC) can control the cyclic
operations of multiple film wrapping or packaging robots.
BACKGROUND OF THE INVENTION
[0003] Various different film wrapping or packaging systems are of
course well known. For example, as disclosed within U.S. Pat. No.
7,707,802 which issued to Forrest on May 4, 2010, several different
types of conventional film wrapping or packaging systems are
disclosed. More particularly, in FIG. 1 of the patent, there is
disclosed a well-known film wrapping or packaging system wherein a
palletized load is placed upon a rotary turntable, and as the
palletized load is rotated by means of the turntable, the load is
wrapped within the film packaging material. In FIG. 2 of the
patent, a palletized load is disposed at a package wrapping
station, and a rotary arm, carrying a carriage with a roll of
packaging film mounted thereon, rotates around the palletized load
thereby wrapping the same within the film packaging material. In
FIG. 3 of the patent, a palletized load is like-wise disposed at a
package wrapping station defined internally within an upstanding
framework, and a carriage, carrying a roll of packaging film, is
rotated around a ring member, thereby wrapping the packaging film
around the palletized load. Still further, as can be appreciated
from FIG. 1 of the present patent application drawings, a
conventional film wrapping or packaging robot 100 is disclosed. The
robot 100 is seen to comprise a motorized unit or vehicle 102
having a suitable drive motor, not shown, operatively connected to
a pair of wheels 104,104, the inside wheel 104 being the drive
wheel such that the robot 100 can effectively circumnavigate around
a palletized load disposed at a package wrapping station. The robot
100 is also seen to comprise an upstanding mast 106 upon which a
support arm 108 is pivotally mounted. A suitable actuator 110 is
operatively connected to the a first proximal end of the support
arm 108, while the second opposite or distal end of the support arm
108 has a film roll housing 112 mounted thereon. A roll of
packaging film 114 is rotatably mounted upon a spindle, not
visible, mounted upon the film roll housing 112. As can thus be
readily appreciated, when the actuator 110 is effectively
retracted, the first end of the support arm 108 is caused to move
downwardly thus elevating the second opposite end of the support
arm 108 so as to accordingly elevate or raise the film roll housing
112 and the roll of packaging film 114. Conversely, when the
actuator 110 is extended, the first end of the support arm 108 will
be elevated so as to cause the film roller housing 112 and the roll
of packaging film 114 to be lowered. The different elevational
levels of the film roll housing 112 and the packaging film 114 can
be accordingly controlled so as to achieve desired wrapping or
packaging of the palletized load in accordance with predetermined
wrapping or packaging patterns.
[0004] While such a conventional film wrapping or packaging robot
operates satisfactorily, such robots can be improved so as to
enhance the efficiency of the overall wrapping or packaging
operations. For example, with the conventional robot, an operator
must initially secure the leading end of the wrapping or packaging
film to the palletized load before initiating the operation of the
robot to commence the film wrapping or packaging operation. In
addition, since only one robot can wrap a palletized load at a
particular location or wrapping station, and while it is possible
to establish multiple wrapping stations at which multiple robots
are respectively disposed so as to individually perform their film
wrapping or packaging operations, each robot requires an operator
for securing the leading end of each wrapping or packaging film to
its respective palletized load, or alternatively, the same operator
needs to effectively service the multiple robots in a serial
manner. In accordance with the first mode of operation, additional
manpower/operators are of course required to service the
multiplicity of robots, whereas in accordance with the second mode
of operation, an increased amount of time is required for the same
operator to serially service the multiple robots. Still yet
further, it often happens that when a robot completes its entire
film packaging or wrapping operation, comprising, for example, a
predetermined number of film layers wrapped around the lower part
of the palletized load and a predetermined number of film layers
wrapped around the upper part of the palletized load, the robot may
conclude its entire film packaging or wrapping operation at a
circumferential location, relative to the palletized load, which is
different from the circumferential location at which the robot
always starts the film packaging or wrapping operation. Additional
time, or operator control or intervention, is therefore effectively
required to relocate the robot to its next load START or HOME
position.
[0005] A need therefore exists in the art for a new and improved
robot system which comprises the use of multiple film wrapping or
packaging robots, wherein the system is substantially entirely
automatic, except for initiating the actual START of the robots,
all of the multiple robots can be controlled by a single or central
controller, and the robots will automatically return to their START
or HOME positions at which they normally start the film packaging
or wrapping operation.
SUMMARY OF THE INVENTION
[0006] The foregoing and other objectives are achieved in
accordance with the teachings and principles of the present
invention through the provision of a new and improved multiple
robot system which comprises a multiplicity of film packaging or
wrapping robots wherein the multiplicity of robots are adapted to
circumnavigate their respective palletized loads in order to
package or wrap the same within packaging or wrapping film, and
wherein further, the multiplicity of robots are individually
wirelessly connected to a single programmable logic controller
(PLC). In this manner, when the operator initiates a START command,
such as, for example, by pushing a START button on the control
panel of the programmable logic controller (PLC), the multiplicity
of robots will be simultaneously actuated so as to perform their
film wrapping or packaging operations. Each robot is individually
programmed so as to wrap or package its particular palletized load
in accordance with a predetermined film packaging or wrapping
pattern. Such a packaging or wrapping pattern may include, for
example, a predetermined number of layers of film to be wrapped
around the bottom of the palletized load, a predetermined number of
layers of film to be wrapped around the top of the palletized load,
the speed at which each robot operates to wrap or package the
palletized load, the inclusion of any overlap or overwrap sections
of the packaging or wrapping film, and the like. In addition, as a
result of the two-way communication effectively established between
the multiple robots and the programmable logic controller (PLC), at
the conclusion of a particular film packaging or wrapping
operation, the individual robot will know its position relative to
the palletized load and relative to its original HOME or START
position whereby the robot will automatically navigate back to its
START or HOME position so as to in fact be ready to commence a new
film packaging or wrapping operation. Still yet further, each one
of the robots is provided with a new mechanism or system for
automatically severing the packaging or wrapping film at the
conclusion of a packaging or wrapping cycle, for retaining the
leading end of the packaging or wrapping film upon the severing
mechanism in preparation for a new packaging or wrapping cycle, and
for attaching the leading end of the packaging or wrapping film to
the palletized load without requiring an operator to perform this
function.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Various other features and attendant advantages of the
present invention will be more fully appreciated from the following
detailed description when considered in connection with the
accompanying drawings in which like reference characters designate
like or corresponding parts throughout the several views, and
wherein:
[0008] FIG. 1 is a perspective view of a first conventional PRIOR
ART robot currently used in connection with the packaging or
wrapping of palletized loads within packaging or wrapping film;
[0009] FIG. 2 is a perspective view of a second conventional PRIOR
ART robot which is similar to the conventional PRIOR ART robot
illustrated within FIG. 1 and which is to be modified in accordance
with the principles and teachings of the present invention so as to
provide the film packaging or wrapping robot industry with a new
and improved robot which is capable of achieving the objectives of
the present invention;
[0010] FIG. 3 is a perspective view of the second conventional
PRIOR ART robot as shown in FIG. 2 but from a different perspective
orientation such that different component parts of the robot are
visible;
[0011] FIG. 4 is a perspective view of a first embodiment of a new
and improved robot, similar to the second conventional PRIOR ART
robot which is illustrated within FIGS. 2 and 3, but which has been
modified so as to include new structural features which will enable
the new and improved robot to operate fully automatically once the
operator has initiated a START control signal;
[0012] FIG. 5 is a perspective view of the new and improved robot
as illustrated within FIG. 4 but from a different perspective
orientation such that the new structural features thereof can be
seen better and therefore be better appreciated;
[0013] FIG. 6 is a schematic drawing illustrating the disposition
of a multitude of robots, such as, for example, three robots, as
more particularly disclosed within FIGS. 4 and 5, wherein the
multitude of robots can be controlled by means of a single
controller such as, for example, a programmable logic controller
(PLC);
[0014] FIG. 7 is a perspective view of a second embodiment of a new
and improved robotic film packaging or wrapping system as
constructed in accordance with the principles and teachings of the
present invention;
[0015] FIG. 8 is an enlarged view of the robotic film packaging or
wrapping system as disclosed within FIG. 7, illustrating in greater
detail the dual guide wheel system and the adhesive strip or
adhesive tape dispensing mechanism as mounted upon the support arm
of the robot vehicle;
[0016] FIG. 9 is an enlarged view of the adhesive strip or adhesive
tape dispensing mechanism, in particular, the mounting of the
adhesive strip or adhesive tape dispensing gun shown in its locked
position upon the gun support plate;
[0017] FIG. 10 is an enlarged view of the adhesive strip or
adhesive tape dispensing mechanism, in particular, the mounting of
the adhesive strip or adhesive tape dispensing gun shown, as shown
in FIG. 8, however, the gun is now shown in its unlocked position
upon the gun support plate;
[0018] FIG. 11 is a perspective view of a proximity sensor utilized
in conjunction with the robot in order to ensure that the robot
vehicle, of the robotic film packaging or wrapping system, is able
to return to its original HOME or START position at the conclusion
of a particular film packaging or wrapping operation in preparation
for the commencement of a new film packaging or wrapping
operation;
[0019] FIG. 12 is a top perspective view of the proximity counter
utilized in conjunction with one of the film feed rollers in order
for personnel to know how much film has been used;
[0020] FIG. 13 is a vertical perspective view of the film clamping
and cutting mechanism for severing the wrapping or packaging film
thereby forming a trailing end portion of the wrapped film which
will self-adhere to the palletized load, and a leading end portion
of the packaging or wrapping film which will be retained in
preparation for a new film wrapping or packaging cycle, wherein the
film clamping and cutting mechanism has been rotated from its
horizontally oriented position to its vertical orientation;
[0021] FIG. 14 is a vertical perspective view of the film clamping
and cutting mechanism as shown in FIG. 13, FIG. 14 more clearly
showing the spatial relationship between the film clamping and
cutting mechanism with respect to the two blocks of foam material
when the film clamping and cutting mechanism is disposed in its
vertical orientation;
[0022] FIG. 15 is front perspective view of the film clamping and
cutting mechanism as shown in FIGS. 13 and 14, FIG. 15 clearly
illustrating the movement of the film clamping and cutting
mechanism to its retention position at which it retains the leading
end portion of the packaging or wrapping film in preparation for a
new film wrapping or packaging cycle after the trailing end portion
of the previous film wrapping or packaging cycle has been
severed;
[0023] FIG. 16 is a perspective view of the actuator assembly, for
the film clamping and cutting mechanism illustrated within FIGS.
13-15, wherein the actuator assembly is disposed at its de-actuated
disposition;
[0024] FIG. 17 is a perspective view of the actuator assemsembly,
for the film clamping and cutting mechanism illustrated within
FIGS. 13-15, wherein the actuator assembly is disposed at its
actuated disposition;
[0025] FIG. 18 is a perspective view illustrating the trailing end
of the robot vehicle of the robotic film packaging or wrapping
system, illustrating the mounting of the roll of packaging or
wrapping film upon the robot vehicle, as well as the film clamping
and cutting mechanism illustrated within FIGS. 13-17 and the
actuator assembly for moving the film clamping and cutting
mechanism toward and away from the palletized load;
[0026] FIG. 19 is a front elevational view showing the use of an
auxiliary or additional bumper pad secured to the large block of
memory foam in order to ensure a sufficient amount of engagement of
pressure is effectively impressed upon the leading end portion of
the wrapping or packaging film when being applied to a side wall
portion of the palletized load;
[0027] FIG. 20 is a perspective view of a third embodiment of a new
and improved robotic film packaging or wrapping system as
constructed in accordance with the principles and teachings of the
present invention;
[0028] FIG. 21 is a perspective view, similar to that of FIG. 20
but from a different angular perspective, of the third embodiment
of a new and improved robotic film packaging or wrapping system as
constructed in accordance with the principles and teachings of the
present invention;
[0029] FIG. 22 is a top plan view of the actuator assembly for
moving the adhesive applicator into engagement with the palletized
load in order to transfer a dot of adhesive material onto the
palletized load in preparation for attaching a leading end portion
of the packaging or wrapping film to the palletized load, wherein
the actuator assembly includes a pair of actuator slide plates;
[0030] FIG. 23 is a top plan view, similar to that of FIG. 22,
partially showing the actuator assembly so as to more clearly show
the compression spring at the forward end of the actuator
assembly;
[0031] FIG. 24 is a perspective view of a bottom support plate of
the actuator assembly that is adapted to be fixedly connected to
the pair of actuator slide plates disclosed within FIG. 22;
[0032] FIG. 25 is a top plan view of a slide track, and a slide
mechanism slidably disposed within the slide track, wherein the
slide track is adapted to be fixedly secured to the bottom support
plate of FIG. 24;
[0033] FIG. 26 is a perspective view of the applicator support
plate which is adapted to be fixedly connected to the slide
mechanism disclosed within FIG. 25;
[0034] FIG. 27 is an enlarged view of the applicator support plate
disclosed within FIG. 26, disclosing the spring connection between
the applicator support plate of FIG. 26 and the bottom support
plate of FIG. 24;
[0035] FIG. 28 is a top perspective view of the applicator support
plate, as disclosed within FIG. 27, having the adhesive dot tape
supply roll, the applicator roller, the idler roller, and the
take-up reel rotatably mounted thereon;
[0036] FIG. 29 is a top plan view of the third embodiment of the
new and improved robotic film packaging or wrapping system showing
the entire applicator assembly of FIGS. 20-29 as mounted upon the
main support arm of the robot vehicle; and
[0037] FIG. 30 is a perspective view similar to that of FIG. 29 but
showing the entire applicator assembly as connected to the robot
vehicle.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
[0038] Referring now to the drawings, and more particularlly to
FIGS. 2 and 3 thereof, a second type of conventional PRIOR ART film
wrapping or packaging robot is disclosed and is generally indicated
by the reference character 200. As will be more fully disclosed and
appreciated hereinafter, this second conventional PRIOR ART film
wrapping or packaging robot 200 will be modified in several ways so
as to effectively achieve the new and improved film wrapping or
packaging robot of the present invention, and for continuity
purposes throughout this disclosure, component parts of the various
robots which correspond to component parts of the first
conventional PRIOR ART film wrapping or packaging robot as
illustrated within FIG. 1 will be provided with corresponding
reference characters except that they will be within the 200
series. More particularly, as can best be seen from FIGS. 2 and 3,
and as was the case with the first conventional PRIOR ART film
wrapping or packaging robot 100 illustrated with-in FIG. 1, the
second conventional PRIOR ART film wrapping or packaging robot 200
is seen to comprise a motorized unit or vehicle 202 having a
suitable drive motor, not shown, operatively connected to the
inside one of a pair of rear wheels 204,204 such that the robot 200
can effectively circumnavigate around a palletized load disposed at
a package wrapping station. The robot 200 is also seen to comprise
an upstanding mast 206 upon which a support arm 208 is pivotally
mounted. A suitable actuator 210 is operatively connected to the a
first proximal end of the support arm 208, while the second
opposite or distal end of the support arm 208 has a film roll
housing 212 mounted thereon. An upstanding spindle 213 is fixedly
mounted upon the film roll housing 212 for rotatably mounting,
holding, and accommodating a roll of packaging film, not shown,
thereon. As can therefore be readily appreciated, and in a manner
similar to that characteristic of the first conventional PRIOR ART
robot 100 illustrated within FIG. 1, when the actuator 210 is
effectively retracted, as can be seen in FIG. 3, the first proximal
end of the support arm 208 is caused to move downwardly thereby
correspondingly lowering the second opposite distal end of the
support arm 208 so as to accordingly lower the film roll housing
212 and the roll of packaging film disposed upon the spindle
213.
[0039] Conversely, when the actuator 210 is extended, the first
proximal end of the support arm 208 will be elevated so as to cause
the film roller housing 212 and the roll of packaging film disposed
upon the spindle 213 to likewise be elevated. The different
elevational levels of the film roll housing 212 and the packaging
film disposed upon the spindle 213 can be accordingly controlled so
as to achieve desired wrapping or packaging of the palletized load
in accordance with predetermined wrapping or packaging patterns. It
is additionally seen that the second conventional PRIOR ART robot
200 is also provided with a feeler mechanism, which may be, for
example, a wheel 216 that is operatively mounted upon the distal
end of a support arm 218, while the proximal end of the support arm
218 is operatively connected to a forward steering wheel assembly
219. This feeler mechanism or wheel 216 is adapted to be disposed
in contact with the palletized load as the robot 200
circumnavigates around the palletized load during the film wrapping
or packaging operation so as to maintain the robot 200 at a
predetermined distance from the palletized load in order to package
or wrap the palletized load in the wrapping or packaging film in a
uniform and consistent manner. The support arm 218 may be
spring-biased or have a fluid shock absorber, not shown,
operatively associated therewith such that when the robot 200,
through means of the feeler or wheel 216, contacts the palletized
load, the spring or shock absorber will effectively accommodate any
contact load or force impressed upon the palletized load such that
no damage is caused to the palletized load.
[0040] With reference now being made to FIGS. 4 and 5, pertinent
portions of a first embodiment of a new and improved robot, which
is generally indicated by the reference character 300 and which
effectively is a robot similar to the robot 200 as illustrated
within FIGS. 2 and 3 but modified in accordance with the principles
and teachings of the present invention, is disclosed. For brevity
purposes, a discussion of the structural components of the first
embodiment of the new and improved robot 300, which are similar to
corresponding structural components of the robot 200, will not be
discussed but have been assigned corresponding reference characters
within the 300 series, with the ensuing disclosure concentrating
upon, or being directed toward, the new and improved features of
the robot 300. More particularly, for example, as can best be seen
from FIG. 4, the film roll housing or framework 312 is fixedly
mounted upon the distal end of the support arm 308 by means of a
mounting bracket 320, and in addition, an actuator 322, which may
be, for example, a suitable piston-cylinder assembly, is fixedly
mounted upon the film roll housing or framework 312. The actuator
or piston-cylinder assembly 322, is provided with an
extensible/contractible piston rod 324, and an applicator plate
326, the purpose of which will be explained more fully hereinafter,
is pivotally mounted upon the free or external end of the piston
rod 324 by means of a pivotal mounting assembly 328 such that the
applicator plate 326 is permitted to pivot when the same comes into
contact with a palletized load so as not to damage the palletized
load as will be more fully explained hereinafter.
[0041] Continuing further, and as can probably best be appreciated
from FIG. 5, a motorized tape dispensing assembly 330 is also
mounted upon the film roll housing or framework 312 by means of a
support plate 332 which is, in turn, fixedly mounted to an
upstanding member 334 of the film roll housing or framework 312. As
can best be seen from FIG. 4, a first drive member 336 is disposed
upon the tape dispensing assembly 330 and is adapted to be driven
by means of a small motor 338 as can best be seen in FIG. 4. The
first drive member 336 is drivingly engaged with a second driven
member 340, such as, for example, by means of a pulley band or the
like, not shown. In addition, the second driven member 340 is
drivingly connected to a pair of capstans 342,344 by means of a
pulley band 346 or other similar drive mechanism. The second driven
member 340 is adapted to have a roll of tape, not shown, disposed
thereon, wherein, for example, a plurality of adhesive dots, also
not shown, are disposed upon the roll of tape. The adhesive dot
tape will be conveyed around or between the pair of capstans
342,344 so as to come into contact with the wrapping or packaging
film which is mounted upon the spindle 313 and which is conveyed
toward the palletized load by means of one or more rollers, one of
which is disclosed at 348, mounted upon the film roll housing or
framework 312.
[0042] The one or more rollers 348 may be either a drive roller, a
tension roller, a stretch roller, or the like, conventionally
provided upon known film packaging or wrapping systems.
Accordingly, when the wrapping or packaging film from the roll of
film disposed upon the spindle 313 comes into contact with the
adhesive dot tape being dispensed from the tape dispensing assembly
330, the adhesive dots will be transferred from the adhesive dot
tape onto the leading end portion of the wrapping or packaging film
because the adhesive affinity defined between the adhesive dots and
the wrapping or packaging film is greater than the adhesive
affinity defined between the adhesive dots and the roll of paper
upon which the dots are initially disposed and which defines the
roll of adhesive dot tape. When one of the adhesive dots is in fact
secured upon the leading end portion of the wrapping or packaging
film, the actuator 322 may then be actuated so as to effectively
act as a plunger mechanism, extending the piston rod 324 and the
applicator plate 326 toward the palletized load, such that the
applicator plate 326 will cause the leading end of the wrapping or
packaging tape, having the adhesive dot secured thereon, to be
adhesively bonded to the palletized load whereby a film wrapping or
packaging operation can commence. It is of course to be noted that
as a result of this adhesive dot application system, the operation
of adhering the leading end portion of the wrapping or packaging
tape to the palletized load is completely automated with no need
for any operator interaction. It is still further noted that the
adhesive member is not to be limited to an adhesive dot but may
comprise an adhesive patch, an adhesive strip, an adhesive label,
or the like.
[0043] With reference now being made to FIG. 6, the schematic
drawing illustrates another important feature of the robot system
of the present invention wherein a multitude of robots 300, as
illustrated within FIGS. 4 and 5, are now disposed adjacent to a
plurality of wrapping or packaging stations or areas 350 at which a
plurality of palletized loads 352 are disposed awaiting to be
wrapped or packaged. A programmable logic controller (PLC) 354 is
also provided within the vicinity of the multitude of robots 300,
and it is schematically illustrated that the single programmable
logic controller (PLC) 354 is effectively linked to each one of the
robots 300 by any suitable type of wireless communication links
356,358,360, such as, for example, blue tooth technology or any
other equivalent thereof. It is to be understood that while, for
example, three robots 300 have been illustrated, the present
invention system can of course be effectively utilized in
conjunction with any number of robots 300, that is, a single robot
300, three robots 300, less than three robots 300, and more than
three robots 300. In this manner, the single programmable logic
controller (PLC) 354 can control a single or a multitude of
automatically operable film wrapping or packaging robots. It is
further seen that each one of the robots 300 will traverse a
circular locus 362 around each palletized load 352, and that each
robot 300 will initiate or commence each film wrapping or packaging
cycle or operation from an initial HOME or START position which
may, for illustrative purposes, be considered to be the six o'clock
position of a clock face. In other words, at the conclusion of a
particular film wrapping or packaging cycle or operation, each
robot 300 will be returned to its START or HOME position in
preparation for the start or commencement of a new film wrapping or
packaging cycle or operation. This is important for the overall
efficiency of the film wrapping or packaging operation as will now
be explained.
[0044] As can readily be appreciated, the programmable logic
controller (PLC) 354 will effectively operatively interface with
each robot 300 so as to initiate the start or commencement of a
film wrapping or packaging cycle or operation, as a result of, for
example, an operator pushing a START button on a console or control
panel, not shown, of the programmable logic controller (PLC) 354.
The programmable logic controller (PLC) 354 will also control all
movements of the robot 300 and the various movable components
thereof, such as, for example, the elevation of the support arm
308, the extensible/contractible movements of the piston rod 324
and the applicator plate 326, and the like, in order to achieve the
desired film wrapping or packaging patterns. Such patterns can
include, for example, a predetermined number of film layers wrapped
around the lower part of the palletized load, a predetermined
number of film layers wrapped around the upper end of the
palletized load, a predetermined number of overlapping or
overwrapping film layers, the degree of overlap or overwrap of such
film layers, the speed of the robots when traversing the circular
loci 362, the speed at which the support arm 308 is elevated or
lowered so as to, in turn, determine, for example, the number of
film layers that will be wrapped around the palletized while
transitioning between the lower end of the palletized load and the
upper end of the palletized load, or the like. Of course the
individual robots 300 can also have their own operational programs
incorporated within their units and these computers or controllers
can likewise interface with the main or primary programmable logic
controller (PLC) 354.
[0045] An interesting additional operational control that can also
be implemented by means of the single programmable logic controller
(PLC) 354, is, as has been alluded to hereinbefore, that the
programmable logic controller (PLC) 354 can effectively ensure that
at the conclusion of a film wrapping or packaging cycle or
operation, each robot 300 is returned to its START or HOME
position. One might wonder that if the robots 300 were programmed
to wrap the palletized load 352 with a predetermined number of
complete film wraps or layers at both the top and bottom of the
palletized load 352, then at the conclusion of the upper and lower
film wrap layers, and therefore at the conclusion of the entire
film wrapping or packaging cycle or operation, the robots 300 would
inherently or by definition be disposed back at their START or HOME
positions. However, this is not necessarily true. Assuming, for
example, that a particular robot 300 has been programmed to wrap
its palletized load 352 with five complete film wraps or layers at
the lower end of the palletized load 352 and five complete film
wraps or layers at the upper end of the palletized load 352. In
addition, depending upon, for example, the vertical height of the
palletized load, the elevation of the support arm 308 will require
more time to reach the upper end of the palletized load when a
particular palletized load is taller than another palletized load.
During the transition between the completion of, for example, all
of the film wraps or layers around the lower end of the palletized
load 352 and the commencement of the film wraps or layers around
the upper end of the palletized load 352, the robot 300 continues
to traverse its circular locus 362. For example, for loads that are
four feet high and six feet high, respectively, it will require
more time for the support arm 308 to reach the top of the six foot
high load than for it to reach the top of the four foot high load,
and during these transition times, the robot 300 continues to
traverse its circular locus 362. Accordingly, the robot 300 will be
disposed at a different circumferential position along the circular
locus 362 depending upon the height of the palletized load.
[0046] Thus, while each film wrap or layer around the lower end of
the palletized load 352 started and ended at, for example, the
START or HOME or six o'clock position, when the support arm 308 has
elevated the film roll housing or framework 312 to its properly
elevated position in preparation for commencement of the film
wrapping or packaging at the upper end of the palletized load which
is four feet high, the robot 300 may not in fact be disposed at its
START or HOME or six o'clock position, but may in fact be disposed
at, for example, a position diametrically opposite the START or
HOME or six o'clock position, that is, at the twelve o'clock
position. For a palletized load that is six feet high, the robot
300 may be disposed at, for example, the three o'clock position. A
photoeye or other sensor, not shown but conventionally provided
upon such mobile robots, will send a signal to the control logic of
the conventional robot that the support arm and the film roll
housing or framework of the conventional robot have now attained
their uppermost positions at which time the film packaging or
wrapping of the upper end portion of the palletized load can now be
commenced. Accordingly, the film packaging or wrapping cycle or
operation will in fact then be commenced and such film packaging or
wrapping cycle or operation will also end or terminate at the
twelve o'clock position. Thus, the robot will not be positioned
back at the START or HOME position in preparation for the
commencement of a new film packaging or wrapping cycle or
operation. In accordance with the present invention, however, the
programmable logic controller (PLC) 354 can control the robots 300
such that regardless of where a particular film packaging or
wrapping cycle or operation terminates, the robots 300 will be
moved immediately back to their START or HOME positions. This can
easily be done, for example, by means of the programmable logic
controller (PLC) 354 keeping track of the lineal or angular
displacement of each robot 300 from its START or HOME position.
[0047] Still yet further, it is also to be appreciated that the
single programmable logic controller (PLC) 354 can of course
simultaneously control the multiple robots 300 or it can
individually control any one of the multiple robots 300. For
example, if one of the palletized loads 352 has not in fact been
delivered to its designated film wrapping or packaging station 350,
or if the particular load 352 has, for some reason, not been
properly placed at the proper position within the film wrapping or
packaging station 350, such as, for example, at the center of the
film wrapping or packaging station 352, the programmable logic
controller (PLC) 354 will not send the appropriate START signal to
that particular robot 300 operatively associated with that
palletized load 352 and that particular film wrapping or packaging
station 350, however, suitable control signals will in fact be sent
to the other robots 300 in connection with which the palletized
loads have been sensed as being present and properly located within
the particular or respective film wrapping or packaging station
350. It is lastly noted that the actual drive mechanism for each
one of the robots 300 may comprise a forward steering wheel
assembly, not shown, which may also be under the control of the
programmable logic controller (PLC) 354 and is similar to the
forward steering wheel assembly 219 of the robot 200 illustrated
within FIG. 2, or alternatively, the circular loci 362, which the
robots 300 traverse, can comprise a magnetic strip, or
particularized paint, which sensors within the robot 300 can
effectively see or track.
[0048] With reference now being made to FIGS. 7-18, a second
embodiment of a new and improved robotic film packaging or wrapping
system, and the various operative components thereof, as
constructed in accordance with the principles and teachings of the
present invention, is disclosed and is generally indicated by the
reference character 400. It is to be noted that operative
components of the second embodiment of the new and improved robotic
film packaging or wrapping system 400, which correspond to
operative components of the first embodiment of the new and
improved robotic film packaging or wrapping system 300 as
illustrated within FIGS. 4-6, will be designated by corresponding
reference characters except that they will be within the 400 and
500 series. Still yet further, for brevity purposes, a discussion
of the structural components of the second embodiment of the
robotic film packaging or wrapping system 400, which are similar to
corresponding structural components of the first embodiment of the
robotic film packaging or wrapping system 300, or which are similar
to the PRIOR ART robotic film packaging or wrapping system 200,
will not be discussed, the ensuing disclosure concentrating upon,
or being directed toward, the new and improved features of the
second embodiment robotic film packaging or wrapping system
400.
[0049] More particularly, as can best be seen from FIGS. 7 and 8,
one of the new and improved structural features or operative
components characteristic of the second embodiment robotic film
packaging or wrapping system 400, as compared to the first
embodiment robotic film packaging or wrapping system 300, or as
compared to the PRIOR ART robotic film packaging or wrapping system
200, is that in lieu of the use of a single feeler mechanism or
guide wheel 216, the motorized unit or robot vehicle 402 of the
second embodiment robotic film packaging or wrapping system 400 is
provided with a pair of feeler mechanisms or guide wheels 416,417.
The provision of the dual guide wheel system 416,417 has been found
to provide better stability for the packaging or wrapping system
400 with respect to the palletized load to be wrapped or packaged,
particularly when the robot 402 is navigating around corners of the
palletized load. As can best be appreciated from FIG. 8, the dual
guide wheels 416,417 are effectively connected together by means of
a tie bar 419 at the center of which is a rotary axle 421. A pair
of vertically dependent axles 422,424 are fixedly mounted within
opposite ends of the tie bar 419, and each one of the dual guide
wheels 416,417 is rotatably mounted upon a respective lower end
portion one of the axles 422,424 by means of rotary bearing
assemblies 423, 425. In addition, an upstanding spindle 427
projects upwardly through the distal or free end portion of the
main support arm 418 of the robot 402, and a connecting bar 429 has
one end thereof pivotally connected to the lower end portion of the
spindle 427 beneath the support arm 418 while the opposite end of
the connecting bar 429 is pivotally connected to the lower end
portion of the rotary axle 421.
[0050] In this manner, the dual guide wheels 416,417 are
effectively free to move in angular modes in order to remain
engaged with sides of the palletized load as the robot 402 moves
about the palletized load. Accordingly, as the robot 402 navigates
a corner of the palletized load, the leading wheel 416, as viewed
in the direction of the movement of the robot 402 around the
palletized load, will first disengage from the side of the
palletized load which has just been wrapped, but due to the pivotal
mounting of the dual guide wheels 416,417 upon the robot 402
through means of the rotary axle 421, the spindle 427, and the
connecting bar 429, as has been described, as well as the constant
or continuous engagement of the dual guide wheels 416,417 with the
palletized load through means of the support arm 418, the tie bar
419 will effectively be caused to pivot around the rotary axle 421
thereby causing or permitting the leading wheel 416 to engage the
next side of the palletized load while the trailing wheel 417 is
still engaged with the previously wrapped side of the palletized
load. This dual guide wheel mounting system therefore permits the
film wrapping or packaging to proceed in a smooth and tight manner
with respect to the palletized load as opposed to, for example, the
use of a single guide wheel system which may cause the robot to
effectively "bounce" or momentarily disengage from the palletized
load as the robot navigates around the corner regions of the
palletized load.
[0051] With continued reference being made to FIG. 8, and with
additional reference being made to FIGS. 9 and 10, it is to be
appreciated that in accordance with the principles and teachings of
the second embodiment robotic film packaging or wrapping system
400, the adhesive dot application system of the first embodiment
robotic film packaging or wrapping system 300 has effectively been
eliminated, and in lieu thereof, there has been incorporated an
adhesive tape or adhesive strip application system or assembly
whereby an adhesive tape or adhesive strip is to be applied to a
side wall portion of the palletized load in order to, in turn,
adhere a leading end portion of the wrapping or packaging film 414
to the adhesive tape and the palletized load in order to commence a
wrapping or packaging film operation with respect to the palletized
load. More particularly, as can initially best be seen from FIG. 8,
a first support plate 431, having a mounting block 433 and a spacer
collar 435 integrally formed therewith, are effectively mounted
upon the support arm 418 so as to be movable therewith, the collar
435 being angularly or pivotally movably mounted upon the
upstanding spindle 427. It is further noted that an additional pair
of collars 437 is also provided in conjunction with the spacer
collar 435 and the mounting block 433 by means of which the first
support plate 431 is not only disposed at a predetermined angle
with respect to the robot support arm 418, but in addition, the
first support plate 431 is disposed at a predetermined height with
respect to the robot support arm 418. An actuator 439 is mounted
upon a side portion of the first support plate 431 and is
operatively connected to a second, linearly slidable actuation
plate 441 that is operatively connected to the first support plate
431 by means of a pair of springs 443. Actuation of the actuator
439 will cause the second actuation plate 441 to move linearly
against the spring bias of the pair of springs 443, whereas when
the actuator 439 is deactuated, the pair of springs 443 will return
the second actuation plate 441 to its original position. A third
gun support plate 445 is pivotally mounted upon the second
actuation plate 441 by means of a pivot mechanism, not shown, and a
corner portion of the third gun support plate 445 is operatively
connected to the second actuation plate 441 by means of a biasing
spring 447.
[0052] With reference now also being made to FIGS. 9 and 10, it is
additionally seen that the adhesive tape or adhesive strip
application system or assembly further comprises a an adhesive tape
or adhesive strip application gun 449. The application gun 449 can
comprise a standard application gun, such as, for example, a
SCOTCH.cndot. ATG 700, and is seen to comprise a gun handle 451, a
trigger mechanism 453, and an adhesive tape or adhesive strip
housing 455. The gun 449 is adapted to be mounted upon the gun
support plate 445, and in order to confine the gun 449 at a
particular position and angular disposition upon the gun support
plate 445, a first upstanding semi-circular ring or barrier is
provided upon the gun support plate 445 as at 457, as can best be
seen in FIG. 9, so as to engage the right end portion of the
housing 455, while a second upstanding semi-circular ring or
barrier is likewise provided upon the gun support plate 445 as at
459, as can best be seen in FIG. 8, so as to engage the left end
portion of the housing 455. While the barriers 457 and 459
effectively serve to secure the position and angular disposition of
the gun 449 at a particular position and orientation upon the gun
support plate 445, the gun 449 is actually locked in place or
locked down onto the gun support plate 445 by means of a
conventional over-center locking mechanism 461 which is clearly
shown in FIGS. 9 and 10.
[0053] As can be seen from FIGS. 9 and 10, the over-center locking
mechanism 461 comprises a base member 463 fixedly secured to the
gun support plate, a locking bar 465, and an operating handle 467.
The base member 463 actually comprises a clevis structure with
pivot pins 469 and 471 extending therethrough. In addition, the
free distal end portion of the operating handle 467 is pivotally
connected to the proximal end portion of the locking bar 465 as at
473, while the operating handle 467 is operatively connected to the
pivot pin 471 by means of a connector member, not shown or capable
of being seen, which connects the pivot pin 471 to another pivot
pin 475. As can be readily appreciated from FIGS. 9 and 10, and in
accordance with well-known operative techniques characteristic of
an over-center locking mechanism, when the operating handle 467 is
pivotally moved to its upward or raised position as shown in FIG.
10, the upward movement of the right, free, or distal end portion
of the operating handle 467 will force the locking bar 465 to move
upwardly, due to the pivotal interconnection between the operating
handle 467 and the locking bar 465 as at 473, such that the locking
bar 465 no longer engages the handle portion 451 of the application
gun 449 whereby the application gun 449 is free to be removed from
its locked position upon the gun support plate 445. Conversely,
downward movement of the right, free, or distal end portion of the
operating handle 467 will force the locking bar 465 to move
downwardly, due to the pivotal interconnection between the
operating handle 467 and the locking bar 465 as at 473, such that
the locking bar 465 is forced into engagement with the handle
portion 451 of the application gun 469 thereby locking the
application gun 449 at its locked position upon the gun support
plate 445.
[0054] Continuing further, and with reference still being made to
FIGS. 8 and 9, a trigger actuator 475, in the form of an upstanding
tubular member, is disposed adjacent to the application gun trigger
mechanism 453 and is fixedly mounted upon a plate 477. The trigger
actuator 475 is operatively connected to the piston rod 479 of a
solenoid actuator 481, and accordingly, when the solenoid actuator
481 is fired and maintained in the ON position, the piston rod 479
is retracted and moved toward the right as viewed within FIGS. 9
and 10 thereby causing the trigger mechanism 453 to be maintained
at its firing position. With reference reverting back to FIG. 8, it
is further seen that a supply roll of an adhesive tape or an
adhesive strip is disposed internally within the adhesive tape or
adhesive strip housing 455 and is disclosed at 483. The adhesive
tape or adhesive strip actually comprises a paper tape or strip
upon which there is disposed a double-sided adhesive tape or strip
wherein one side of the double-sided adhesive tape or strip has a
substantially larger adhesive affinity for or with respect to the
palletized load than for or with respect to the paper backing tape
or strip. Accordingly, When the side of the double-sided adhesive
tape or strip, which has the larger adhesive affinity, is
effectively forced into contact with the palletized load, it will
effectively release from the paper backing strip and stick to the
palletized load. In order to achieve the dispensing of the adhesive
strip or tape from its supply roll 483, a braking roller 485 and an
idler application roller 487 are mounted upon suitable support
brackets, not shown, at a position adjacent to an outlet or output
port of the adhesive tape or adhesive strip housing 455 whereby the
two rollers are disposed in peripheral contact with each other such
that the idler application roller 487 is caused to rotate as a
result of its contact engagement with the palletized load 452 with
the braking roller 485 permitting the idler application roller 487
to rotate. The adhesive tape or adhesive strip will exit the
housing 455 and be routed around an external peripheral portion of
the braking roller 485 and effectively be inserted or threaded into
the nip defined between the braking roller 485 and the idler
application roller 487. The highly sticky side of the double-sided
adhesive tape will be disposed in contact with the braking roller
485 while the paper-backing portion of the double-sided adhesive
tape will be disposed in contact with the idler application roller
487.
[0055] The braking roller 485 is treated with a suitable substance
so as to prevent the highly sticky side of the double-sided tape
from sticking thereto, and therefore, as the adhesive tape or strip
moves around the outer peripheral surface of the idler application
roller 487, the highly sticky side of the double-sided adhesive
tape or strip will effectively face outwardly from the idler
application roller 487 and will be disposed toward the palletized
load 452. As can also be seen from FIG. 8, the gun housing 455 also
includes a take-up reel 489 for the paper backing of the
double-sided adhesive tape or strip, wherein the take-up reel 489
may be driven when the trigger mechanism 453 is activated.
Alternatively, the take-up reel 489 can be operatively connected to
the idler application roller 487 such that as the idler application
roller 487 rotates and deposits the adhesive tape or strip onto the
palletized load 452, the take-up reel 489 is being rotated so as to
take-up the paper backing strip or tape. The braking roller 485 is
also operatively connected to the trigger mechanism 453.
Accordingly, when the solenoid 481 is deactivated, the trigger
mechanism 453 is released and the braking roller 485 is braked or
prevented from rotating, thereby, in turn, effectively braking the
idler application roller 487 such that the idler application roller
487 no longer rotates and no long dispenses the adhesive tape or
adhesive strip onto the palletized load 452. The robot vehicle 402
continues to move however, thereby causing the adhesive tape to
sever while the paper backing of the double-sided adhesive tape or
strip remains intact. This operation will be explained in greater
detail later in the specification.
[0056] With reference now being made to FIG. 11, another new and
unique feature characteristic of the robot vehicle 402 of the
second embodiment of the robotic film packaging or wrapping system
of the present invention will now be described. It has previously
been noted with respect to the PRIOR ART robotic systems as
disclosed within FIGS. 1-3, as well as with respect to the first
embodiment of the robotic film packaging or wrapping system of the
present invention as disclosed within FIGS. 4-6, that it is
important to not only know where the robot vehicle 402 will be
located relative to its original HOME or START position, but more
importantly, that the robot vehicle 402 can be returned to its
original HOME or START position in preparation for the commencement
of a new film wrapping or packaging operation. Accordingly, the
robot vehicle 402 has been provided with a proximity sensor 491,
and the floor region of the wrapping station 450 has been provided
with a metal plate 493 suitably secured to the particular floor
region of the wrapping station 450 designating the HOME or START
position of the robot vehicle 402. Accordingly, after completion of
a particular film wrapping or packaging operation, the programmable
logic controller (PLC) 454, operatively connected to the robot
vehicle 402 through means of the suitable communication links 456,
will cause the robot vehicle 402 to circumnavigate the palletized
load, regardless of where the robot vehicle 402 is with respect to
the palletized load and with respect to the HOME or START position,
until the proximity sensor 491 detects the metal plate 493,
indicating the HOME or START position, at which time the
programmable logic controller (PLC) 454 will terminate the motor
drive of the robot vehicle 402. For best results using the
proximity sensor 491 in connection with the metal plate 493 in
order to detect the START or HOME position, it has been determined
that the proximity sensor 491 should be approximately one inch
(1.00'') in diameter and that it should be secured to a side
portion of the robot vehicle 402 such that the proximity sensor 491
is located approximately eight centimeters (8 cm) above the metal
plate 493.
[0057] With reference now being made to FIG. 12, still another new
and unique feature characteristic of the robot vehicle 402 of the
second embodiment of the robotic film packaging or wrapping system
of the present invention will now be described. In connection with
all film wrapping or packaging systems, it is always important to
know how much wrapping or packaging film is being utilized in
connection with the wrapping or packaging of a particular load. For
example, such data may be desired for efficiency-improvement
purposes. In other words, wrapping or packaging installations may
desire to vary their wrapping or packaging techniques so as to
reduce the amount of film required to wrap or package a particular
load. Alternatively, such data may be used as a means for
accurately tracking how much film is being used for particular
wrapping or packaging operations in connection with which the
wrapping or packaging installation is only required to pay for the
film actually used.
[0058] Accordingly, in accordance with the principles and teachings
of the present invention, the upper end portion of one of the
wrapping or packaging film dispensing roller axles 495 is provided
with a plurality of studs or bosses 497. In particular, four of
such studs or bosses 407 are fixedly mounted upon the upper end
portion of the particular film roller axle 495 at equiangularly
spaced locations, that is, 90.degree. apart. A proximity counter
499 is disposed adjacent to the upper end portion 495 of the
particular roller axle, and accordingly, as the roller axle
rotates, the plurality of studs or bosses 497 rotate past the
proximity counter 499. The proximity counter 499 can therefore
count the number of studs or bosses 497 passing thereby, such data
can be transmitted to the programmable logic controller (PLC) 454,
and knowing the diameter of the particular roller, which could be
an idler roller, a stretch roller, or the like, a determination can
be derived as to how much wrapping or packaging film has been
unwound from its supply roll and wrapped upon the palletized
load.
[0059] A last new, novel, and unique structural feature
characteristic of the new and improved second embodiment of the
robotic film packaging or wrapping system 400 of the present
invention will now be described with reference being made to FIGS.
13-18. More particularly, FIGS. 13-18 are concerned with a new and
improved film cutting and clamping mechanism, and an operative
assembly for appropriately moving the same, whereby at the
conclusion of a particular film wrapping or packaging operation,
the wrapping or packaging film is severed so as to effectively
create a trailing end portion of the wrapping or packaging film
which effectively self-adheres to the palletized load, while
simultaneously creating a leading end portion of the wrapping or
packaging film which is retained so as to be utilized to commence
the next film wrapping or packaging operation in connection with a
new palletized load. In accordance with the principles and
teachings of the present invention, it is seen from FIGS. 13-18
that a substantially C-shaped mounting plate or bracket 501 has a
pair of memory foam members 503,505 mounted upon the front face
thereof, that is, the face that is disposed toward the palletized
load. In addition, a clamping plate 507 is provided, and a cutting
implement 509 is fixedly mounted upon the clamping plate 507. The
clamping plate 507 is fixedly mounted upon the distal end portion
of a horizontally oriented rod member 511 wherein the horizontally
oriented rod member 511 passes through the mounting plate 501 so as
to be operatively connected to suitable actuating mechanisms
mounted upon the back or rear side of the mounting plate 501 as
will become more apparent hereinafter. The rod member 511 is both
linearly movable in the horizontal direction along its axis, and
rotatable through an angular extent of 90.degree. about its
longitudinal axis, whereby two different or separate operative
positions with respect to its longitudinal axis are defined.
[0060] It is initially to be appreciated that the clamping plate
507 and the cutting implement 509 are normally spaced away from the
wrapping or packaging film and are disposed upon one side of the
packaging or wrapping film while the palletized load 452 is
disposed upon the opposite side of the packaging or wrapping film,
that is, during a film packaging or wrapping operation. The
exception to this relative state of the various structural
components with respect to each other is when a film packaging or
wrapping operation is being completed at which time the packaging
or wrapping film is about to be severed by the cutting implement
509 in order to effectively create the trailing end portion of the
packaging or wrapping film which will effectively self-adhere to
the packaged or wrapped palletized load, and the leading end
portion of the packaging or wrapping film which will be retained by
the clamping plate 507 in preparation for the commencement of a new
film packaging or wrapping operation. It is to be noted that, as
can best be seen from FIG. 13, the cutting implement 509 includes a
knife edge or similar cutting or severing structure 513 for
performing the severance of the packaging or wrapping film. FIG. 14
clearly illustrates how the rod member 511 passes through the
mounting plate or bracket 501, and FIGS. 15 and 16 illustrate the
various structural components for moving the horizontally oriented
rod member 511 linearly along its horizontally oriented axis as
well as for rotating the rod member 511 around its horizontally
oriented axis. As may be readily appreciated, since the clamping
plate 507 and the cutting implement 509 are fixedly mounted upon
the free distal end portion of the horizontally oriented rod member
511, then the linear and angular movements of the rod member 511
will cause cutting implement 509 to undergo similar movements.
[0061] As can be seen from FIGS. 15 and 16, a horizontal platform
515 is fixedly attached to a rear face 517 of the mounting plate or
bracket 501, and a substantially vertically oriented actuator 519
is mounted upon the platform 515. The actuator 519 comprises a
cylinder 521 and a piston 523, and it is also seen that the rod
member 511 is fixedly disposed within a collar 525 which is
rotatably mounted upon the mounting plate or bracket 501 through
means of a suitable bearing assembly 527. The piston rod 523 is
fixedly connected to an ear or circular disk 529, and the ear or
circular disk 529 is, in turn, fixedly connected to a connector
block 531 which is fixedly connected to an outer peripheral or
tangential portion of the collar 525 which is radially offset from
the longitudinal axis of the rod member 511. Accordingly, when the
piston 523 of the actuator 519 is moved from its retracted position
illustrated within FIG. 16 to its extended position illustrated
within FIG. 17, the collar 525 has effectively been rotated
approximately 90.degree. in the clockwise direction, and
consequently, the rod member 511, along with the clamping plate 507
and the cutting implement 509, have also been rotated through such
an angular extent. Therefore, the clamping plate 507 and the
cutting implement 509 have been rotated, for example, from an
initially horizontally oriented position to a vertically downward
position, the significance of which will become clearer
hereinafter.
[0062] Continuing still further, and with reference still being
made to FIGS. 16 and 17, it is further seen that a horizontally
oriented actuator 533 is also fixedly mounted upon the rear face
517 of the mounting plate or bracket 501, and that the horizontally
oriented actuator 533 comprises a cylinder 535 and a piston 537
which cannot be seen very well within FIG. 16 but can in fact be
seen quite clearly within FIG. 17. The actuator cylinder 535 has an
upstanding square-shaped bracket or collar 539 fixedly mounted
thereon, and the bracket or collar 539 is, in turn, fixedly mounted
upon the horizontally oriented rod member 511. It is noted that
contrary to the normal actuation of a typical conventional actuator
wherein the piston is the relatively movable component of the
piston-cylinder assembly, in this case, the actuator cylinder 535
is the movable component in view of the fact that the piston 537 is
fixedly attached to the rear face 517 of the mounting plate or
bracket 501. As a result of the longitudinal movement of the
actuator cylinder 535 in the rearward direction away from the rear
face 517 of the mounting plate or bracket 501, and the fixation of
the actuator cylinder 535 to the rod member 511 through means of
the collar or bracket 539, the rod member 511, along with the
clamping plate 507 and the cutting implement 509, are also moved in
the rearward direction. Considered conversely, however, the
clamping plate 507 and the cutting implement 509 are effectively
moved toward the front face 541 of the mounting plate or bracket
501. More particularly, as can also be best appreciated from FIGS.
14 and 15, as the clamping plate 507 and the cutting implement 509
are moved toward the front face 541 of the mounting plate or
bracket 501, the cutting implement 509 encounters the packaging or
wrapping film 543 extending from the palletized load 452 and will
sever the packaging or wrapping film 543 thereby forming a trailing
end portion of the packaging or wrapping film 543 which will
self-adhere to the palletized load, while the clamping plate 507
forcefully engages the small block of memory foam 503 so as to
fixedly retain a leading end portion of the packaging or wrapping
film 543 which is now actually stretched taut across the large
block of memory foam 505 as seen in FIG. 15.
[0063] With reference lastly being made to FIG. 18 in connection
with the various structural components comprising the second
embodiment robotic film packaging or wrapping system 400, it is
seen that the upstanding packaging or wrapping film roll spindle
413 is fixedly secured upon a film dispensing roller housing 412,
and that the film dispensing roller housing 412 is provided with a
framework which is pivotally attached thereto. More particularly,
it is seen that the framework comprises a vertically oriented bar
or rod 545 that is pivotally mounted upon the film dispensing
roller housing 412 so as to be pivotal about the longitudinal axis
of the vertically oriented bar or rod 545, and three horizontally
oriented, vertically spaced bars or rods 547,549,551 which are
fixedly mounted to lower, middle, and upper portions of the
vertically oriented bar or rod 545. A mounting bracket 553 extends
outwardly from the floor or lower platform 555 of the film
dispensing roller housing 412, and an actuator 557 is fixedly
attached to the floor or platform 555 and the lower horizontal bar
547 of the framework.
[0064] In addition, it is seen that the mounting plate or bracket
501 is pivotally mounted upon free distal end portions of the
horizontally oriented middle and upper bar or rod members 549,551
of the framework as at upper and lower pinions 559, only the upper
one being visible. In this manner, when the actuator 557 is
actuated so as to extend or retract the piston thereof (not
visible), the framework is able to be moved toward or away from the
palletized load 452 which will, in turn, move C-shaped mounting
bracket or plate 501, and the clamping plate 507 and the cutting
implement mounted 509 mounted thereon, toward or away from the
palletized load 452. When the mounting bracket or plate 501 is
moved into engagement with the palletized load 452, it is desired
that the mounting bracket or plate 501, having the large block of
memory foam 505 mounted thereon, be flush with the palletized load
452 such that the leading end portion of the packaging or wrapping
film 543 can be properly applied to the palletized load 452. In
order to ensure this flush disposition of the mounting bracket or
plate 501, and to further ensure that the mounting bracket or plate
501 does not move or pivot too far backwardly beyond the flush
position, a strong coil spring 561 is mounted around the lower
pinion 559 with opposite ends 563,565 of the coil spring 561 being
connected to the mounting bracket or plate 501 and to the middle
framework bar or rod 549, respectively. If desirable, for spatial
considerations, or for locating the mounting bracket or plate 501,
with its various operative components thereon, at a particular
trailing-end location with respect to the robot vehicle 402, the
various horizontally oriented framework members 547, 549,551 may
comprise telescopic structures.
[0065] Having described substantially all of the structural
components of the second embodiment robotic film packaging or
wrapping system 400, a brief description of some of the important
operations of the same will now be described. The first operation
that will be described is the attachment of the leading end portion
of the packaging or wrapping film 543 onto the palletized load 452
as the leading end portion of the packaging or wrapping film 543 is
disclosed within FIG. 15 as being effectively clamped onto the
smaller block of memory foam 503 by means of the clamping plate 507
and with an adjacent portion of the packaging or wrapping film 543
extending across the larger block of memory foam 505 in a taut
manner. The film packaging or wrapping operation is begun with the
robot vehicle 402 disposed near a corner portion of the palletized
load 452 and the support arm 418 is moved in a clockwise direction,
with respect to the robot vehicle 402, so as to effectively bring
the dual guide wheels 416,417 into engagement with the corner
portion of the palletized load 452 such that one of the guide
wheels 416 is disposed in engagement with one side of the
palletized load 452 while the other guide wheel 417 is disposed in
engagement with another side of the palletized load 452. The robot
vehicle 402 itself then begins to move in a clockwise direction
around the palletized load 452 such that the robot vehicle 402 and
the support arm 418 now move in a clockwise direction relative to
the dual guide wheels 416,417.
[0066] Accordingly, as can best be appreciated from FIG. 8, since
the support arm 418 is moving in the clockwise direction relative
to the guide wheels 416,417, the entire adhesive tape or adhesive
strip assembly, comprising the gun 449 and the idler application
roller 487 are also rotated in the clockwise direction whereby the
idler application roller 487, having the highly sticky adhesive
side of the adhesive tape or strip disposed upon its outer
peripheral surface, will now approach the palletized load 452 and
will be at approximately the same radially outward extent as the
outer peripheral surfaces of the dual guide wheels 416,417. At this
point in time, the actuator 439 is actuated so as to linearly move
and extend the actuation plate 441 so as to in fact move the idler
application roller 487 further into engagement with the palletized
load 452, the solenoid 481 is activated so as to activate the
trigger mechanism 453 which drives the take-up reel 489 and
releases the braking roller 485, and the adhesive tape or adhesive
strip is engaged with and applied to a side wall portion of the
palletized load 452. Due to the greater adhesive affinity defined
between the adhesive tape or adhesive strip and the palletized load
452 than the adhesive affinity defined between the adhesive tape or
adhesive strip and its paper backing, the adhesive tape or adhesive
strip is transferred from the paper backing to the palletized load
452. It can therefore be appreciated that as the robot vehicle 402
continues to move forward relative to the palletized load 452, the
top, spring-biased gun support plate 445 will pivot further causing
a predetermined portion of the adhesive tape or adhesive strip to
unroll from the idler application roller 487 and be forcefully
applied onto the palletized load 452. After a predetermined amount
of the adhesive tape or adhesive strip is applied to the palletized
load 452, the solenoid 481 is deactivated, the trigger mechanism
453 is deactivated, and further dispensing of the adhesive tape or
adhesive strip is terminated as a result of the braking roller 485
braking or stopping rotation of the idler application roller 487.
The idler application roller 487 then simply moves away from the
palletized load 452 due to the continued movement of the robot
vehicle 402 with respect to the palletized load 452 whereby the
actual adhesive tape or adhesive strip effectively snaps or breaks,
while the paper backing remains intact, due to the significant
difference in tensile strength between the adhesive strip or
adhesive tape material as compared to that of the paper backing
material, and the spring 447 returns the spring-biased gun support
plate 445 to its original position.
[0067] Having now applied an adhesive tape or adhesive strip to the
palletized load 452, the robot vehicle 402 continues to
circumnavigate the palletized load 452 and when the rear end of the
robot vehicle 402, upon which the leading end portion of the
packaging or wrapping film 543 is located as a result of being
clamped onto the small block of memory foam by means of the
clamping plate 507, and extending across the large block of memory
foam 505 which will serve as an application pad for applying the
leading end portion of the packaging or wrapping film 543 onto the
palletized load 452, as can be appreciated from FIGS. 15 and 18,
the actuator 557 is actuated so as to move the framework 545 and
the C-shaped mounting plate or bracket 501 toward the palletized
load 452 whereby the leading end portion of the packaging or
wrapping film 543 can now be brought into contact with the adhesive
strip or adhesive tape that has been previously affixed to the
palletized load. Continued movement of the robot vehicle 402
effectively "wipes" the leading end portion of the packaging or
wrapping film 543 onto the adhesive tape previously applied to the
palletized load whereupon the robot vehicle 402 can continue to
circumnavigate the palletized load 452 thereby wrapping the
palletized load 452 with the packaging or wrapping film in a
predetermined manner or in accordance with a predetermined mode or
pattern. In order to further ensure that the leading end portion of
the packaging or wrapping film 543 is in fact sufficiently engaged
and pressed onto the palletized load 452, particularly where, for
example, a particular carton or box of the palletized load has an
uneven or concave surface portion, an additional or auxiliary
bumper pad 566, as illustrated within FIG. 19, may be fixedly
secured to the large block of memory foam 505.
[0068] It is of course to be appreciated that once the leading end
portion of the packaging or wrapping film 543 has been secured to
the adhesive strip or adhesive tape disposed upon the palletized
load 452, the actuator 519 is actuated so as to pivot the clamping
plate 507 and the cutting implement 509 from their vertically
downward position, at which the clamping plate 507 has clampingly
retained the leading end portion of the packaging or wrapping film
543 upon the small block of memory foam 503, to their horizontal
positions at which the clamping plate 507 and the cutting implement
509 are located above the upper edge portion of the packaging or
wrapping film 543 so as to effectively be completely cleat of and
disengaged from the packaging or wrapping film 543. The actuator
533 is also actuated so as to retract the clamping plate 507 and
the cutting implement 509 away from the packaging or wrapping film
543, as is the actuator 557 so as to also retract the framework
assembly 545 away from the palletized load 452. It is lastly noted,
as can best be seen in FIG. 15, that the lower end portion of the
clamping plate 507 is provided with a freely rotating wheel or
roller 567 such that when the clamping plate 507 and the cutting
implement 509 are pivotally rotated from their vertically downward
positions to their horizontal positions, the wheel or roller 567
effectively enables the clamping plate 507 to freely move or roll
over the packaging or wrap-ping film 543 without snagging the
same.
[0069] Lastly, when the film packaging or wrapping operation is
completed, reverse operations are implemented in connection with
the clamping plate 507 and the cutting implement 509 in order to
sever the packaging or wrapping film 543 and thereby effectively
form a trailing end portion of the packaging or wrapping film,
which will self-adhere to the palletized load, and a leading end
portion of the packaging or wrapping film 543 which will be
retained upon the small block of memory foam 503 by means of the
clamping plate 507. More particularly, when the film packaging or
wrapping operation is completed, the actuator 557 is actuated so as
to move the framework 545 and the C-shaped mounting plate or
bracket 501 toward the film wherein such components are, at this
time, upon the outside or to the rear of the packaging or wrapping
film. Actuator 519 is then actuated so as to rotate the rod member
511 and thereby move the clamping plate 507 and the cutting
implement 509 to their horizontal positions above the upper edge
portion of the packaging or wrapping film 543, and the actuator 533
is actuated so as to move the rod member 511 linearly forwardly so
as to effectively move the clamping plate 507 and the cutting
implement 509 in the forward direction whereby the clamping plate
507 and the cutting implement 509 are now moved over the upper edge
portion, or across the boundary, of the packaging or wrapping film
543 and will effectively be disposed upon the inside of the
packaging or wrapping film 543. The robot vehicle 402 is at this
time stopped, and the actuator 519 is actuated so as to effectively
rotate the clamping plate 507 and the cutting implement 509
downwardly from their horizontal positions to their vertically
downward positions. Substantially simultaneously, the actuator 533
is also actuated so as to effectively retract the clamping plate
507 and the cutting implement 509 rearwardly such that as the
cutting implement 509 encounters a body portion of the taut
packaging or wrapping film 543, it will sever the same leaving the
trailing edge portion of the packaging or wrapping film to
self-adhere to the palletized load 452 while the clamping plate 507
will capture and retain the leading end portion of the packaging or
wrapping film 543 onto the small block of memory foam 503 as is
shown in FIG. 15. The apparatus is then ready for a new packaging
or wrapping operation.
[0070] With reference now being made to FIGS. 20-30, pertinent
portions of a third embodiment of a new and improved robot, which
is generally indicated by the reference character 600 and which is
effectively a robot similar to the second embodiment robot 400 as
illustrated within FIGS. 7-19 but modified in accordance with the
principles and teachings of the present invention, is disclosed.
For brevity purposes, a discussion of the structural components of
the third embodiment of the new and improved robot 600, which are
similar to corresponding structural components of the second
embodiment robot 400, will not be discussed in detail but have been
assigned corresponding reference characters within the 600 and 700
series. To the contrary, the ensuing disclosure will concentrate
upon, or be directed toward, the new and improved features of the
third embodiment of the robot 600 that, as will become more
apparent hereinafter, deal with the applica-tion of adhesive dots,
or the like, to the palletized load such that a leading end portion
of a packaging or wrapping film is able to be automatically applied
to the palletized load, and the actuator structure for achieving
the application of the adhesive dots to the palletized load.
[0071] More particularly, with reference first being made to FIGS.
20 and 21, the primary difference that can readily be appreciated
between, for example, the third embodiment robot system 600 as
disclosed within FIGS. 20 and 21, and the second embodiment robot
system 400 as disclosed within FIGS. 7 and 8, resides in the
adhesive applicator subsystem or subassembly as will become more
apparent hereinafter. More specifically, it is initially noted, for
example, that the main support arm 618 of the robot 602 has a
substantially elongated Z-shaped configuration, that the vertically
disposed axles 622,624 supporting the dual guide wheels 616,617 are
taller or longer than their counterparts 422,424, that the
vertically oriented spindle 627 rotatably mounted within the free
or distal end portion of the main support arm 618 of the robot 602
is likewise taller or longer than its counterpart 427, and that the
adhesive application subassembly or subsystem is fixedly mounted
upon the lower end portion of the vertically oriented spindle 627
but at an elevational level that is just above the dual guide
wheels 616,617. This structural arrangement of the variously noted
system components permits the components to be spatially
accommodated in an optimal manner while also permitting the
variously noted system components to be optimally located with
respect to the palletized load 652.
[0072] With reference now being additionally made to FIGS. 22-30,
the individual components, comprising the adhesive application
system, as well as their overall operative intercooperation with
respect to each other, will now be described. As can best be
appreciated from FIGS. 20-23, an actuator assembly for moving the
adhesive applicator roller into engagement with the palletized
load, as will be more fully described hereinafter, is seen to
comprise a bottom plate 654 upon which a suitable actuator 656 is
fixedly mounted. A slide housing 658 is also mounted upon the
bottom plate 654 adjacent to the actuator 656, and a pair of slide
plates 660,662, which are slidably disposed atop the slide housing
658, are operatively connected to a screw actuator or rotary drive
rod 664 which can best be seen in FIGS. 22 and 23. As the actuator
656 is actuated to rotate the screw actuuator or rotary drive rod
664 in a first direction, the slide plates 660,662 will move
translationally forwardly along the slide housing 658 toward the
palletized load. The slide plates 660,662 effectively serve as
actuators for limit switches, not shown, so as to effectively
define the travel limits, that is, the extension and contraction,
or disposition, of the application roller with respect to the
palletized load. When the slide plates 660,662 are moved forwardly
toward the palletized load, the forward slide plate 660 will
eventually actuate its associated limit switch such that the
actuator 656 is deactuated whereby the application roller will be
disposed at and maintained at its forwardmost position so as to be
engaged with the palletized load. At a predetermined time
controlled by a programmable logic controller (PLC), the actuator
656 will again be actuated so as to rotate the screw actuator or
rotary drive rod 664 in the opposite direction which will cause the
slide plates 660,662 to be moved in the opposite or rearward
direction away from the palletized load such that the rear slide
plate 662 will actuate its associated limit switch whereby the
actuator 656 will be deactuated.
[0073] As can additionally best be seen from FIGS. 20 and 23, a
pair of vertically spaced collars 668,670 are mounted upon the
vertically upstanding spindle 627 and are fixedly secured to the
spindle 647 by means of, for example, a pair of set screws, not
shown, which tightly grip external peripheral portions of the
spindle 647. In addition, as best seen in FIG. 23, a semi-circular
housing 672 is fixedly secured to the pair of collars 668,670 by
any suitable means, such as, for example, welds as shown at 674,
and a substantially L-shaped angle iron 676 has its vertically
oriented leg 678 fixedly secured to the housing 672 by means of
fasteners 680, while the horizontally oriented leg 682 is fixedly
secured to the bottom plate 654 of the actuator assembly by means
of fasteners 684. In this manner, the actuator assembly is
rotatably or pivotally mounted upon the upstanding spindle 647.
[0074] Continuing further, and with reference now being made to
FIG. 24, there is shown a bottom support plate 686 which is
provided with a plurality of holes or apertures 688. As can be seen
from FIGS. 22 and 23, each one of the slide plates 660,662 is also
respectively provided with a plurality of holes or apertures
690,692, and in this manner, the bottom support plate 686 is
adapted to be fixedly secured to the upper surface portions of the
pair of slide plates 660,662 by means of suitable fasteners, not
shown. In FIG. 25, there is disclosed a slide track 694 which is
also provided with several apertures or holes 696 whereby the slide
track 694 can be fixedly secured atop the bottom support plate 686
by means of suitable fasteners, also not shown. A slide mechanism,
comprising a slide member 698 and a slide plate 700, is adapted to
be slidably disposed within the slide track 694 as a result of the
slide member 698 being slidably disposed upon the upper surface
portion of the slide track 694 and between slide track guide
surfaces or edge portions 702 extending along oppositely disposed,
longitudinally oriented sides of the slide track 694. The slide
plate 700 is adapted to be fixedly secured to the underlying slide
member 698 by any suitable means, such as, for example, fasteners,
not shown, which may be inserted through holes or apertures 704
formed within the slide plate 700. As can best been seen in FIG.
26, there is disclosed an applicator support plate 706 upon which
the various components of the adhesive dot applicator assembly are
adapted to be supported. More particularly, it is seen that the
applicator support plate 706 has a substantially L-shaped
configuration with the central portion of the long leg 705 of the
applcator support plate 706 accommodating fasteners which pass
therethrough so as to engage holes or apertures 708 defined within
the corner regions of the slide plate 700, such fasteners being
shown at 710 in FIG. 26.
[0075] The short leg 712 of the applicator support plate 706 is
provided with an aperture 714 which is adapted to accommodate a
spindle, not shown, of an adhesive dot supply roll 716 as can best
be seen in FIG. 28, such that the adhesive dot supply roll 716 is
rotatably mounted upon the applicator support plate 706. In a
similar manner, the central portion of the applicator support plate
706 is also provided with another aperture 718, within the vicinity
of the fasteners 710, for accommodating a spindle, not shown, of an
adhesive dot backing paper or strip take-up reel 720 which is also
best seen in FIG. 28 and which is also rotatably mounted upon the
applicator support plate 706. FIG. 28 also discloses the fact that
the adhesive dots 722 are releasably mounted in a serially spaced
array upon a backing paper, strip, or the like 724 wherein, after a
series of the adhesive dots 722 are applied to the palletized load,
in a manner similar to the application of the adhesive dots of the
first embodiment of the robotic film packaging or wrapping system
300, the backing paper, strip, or the like 724 is taken up by the
take-up reel 720. As can also best be appreciated from FIG. 28, the
substantially L-shaped applicator support plate 706 is also
provided with a pair of ears or extensions, the first for-wardly
extending ear or extension 726 having the adhesive dot applicator
roller 728 rotatably mounted thereon, whereas a transversely
extending second ear or extension 730 has an idler roller 732
roatably mounted thereon.
[0076] Having described substantially all of the operative
components of the third embodiment robotic film packaging or
wrapping system 600, a brief description of the operation of the
same will now be set forth. When a film packaging or wrapping
operation or cycle is to be commenced, the programmable logic
controller (PLC) 754 will transmit a START signal to the robot
vehicle 602, and the robot vehicle 602 will begin to commence its
path around the palletized load 652. The programmable logic
controller (PLC) 754 will receive signals from the drive wheel
assembly of the robot vehicle 602, and will therefore transmit a
signal to the application actuator 656 at a predetermined time such
that the application actuator 656 can be fired so as to linearly
move the slide assembly comprising the slide plates 660,662, the
bottom support plate 686, the slide track 694, the slide mechanism
698,700, and the applicator support plate 706, in the forward
direction such that the adhesive dot applicator roller 728 will
move into engagement with the palletized load. As can best be seen
in FIG. 20, the predetermined time at which the application
actuator 656 is fired would optimally be at approximately time at
which the robot vehicle 602 would approach the second palletized
load indicia as noted at 734. In this manner, sufficient surface
area of the palletized load 652 is available upon which a
sufficient number of applicator dots 722 can be applied to the
palletized load 652 in preparation for the leading end of the
packaging or wrapping film 543 to be impressed upon and adhered to
the adhesive dots 722 secured to the palletized load 652. It is to
be noted that when the applicator actuator 656 is fired, it will
move all of the aforenoted structural components, that is, the
slide assembly comprising the slide plates 660,662, the bottom
support plate 686, the slide track 694, the slide mechanism
698,700, the applicator support plate 706, and the adhesive dot
applicator roller 728 to the forwardmost position at which the
adhesive dot applicator roller 728 will engage the palletized
load.
[0077] However, due to the aforenoted rotary screw drive 664 within
the slide housing 658, the applicator roller 728 does not contact
the palletized load 652 with sufficient force to damage the
palletized load 652. In addition, it will also be recalled that the
slide assembly comprising the slide member and the slide plate
698,700 are slidably disposed within the slide track 694, and that
the applicator roller 728 is fixedly connected or mounted upon the
slide member and slide plate 698,700 through means of the
applicator support plate 706. Accordingly, when the applicator
roller 728 encounters the palletized load 652, slide mechanism
comprising the slide member and the slide plate 698,700, along with
the applicator roller 728 as mounted upon the applicator support
plate 706, will tend to move backwardly or away from the palletized
load 652. In order to effectively prevent this, and to maintain the
applicator roller 728 in engagement with the palletized load 652,
it is noted, as can best be seen in FIGS. 24, 26, and 27, that a
plurality of holes or apertures 736 are provided within a side edge
portion of the bottom support plate 686. As can best be seen in
FIGS. 26 and 27, a screw or bolt 738 is disposed within one of the
holes or apertures 736, and one end of a coil spring 740 is
connected to the bolt or screw 738. The applicator support plate
706 is provided with a dependent lug 742, and a second opposite end
of the coil spring 740 is connected to the lug 742. In this manner,
the retrograde movement of the aforenoted components, including the
applicator support plate 706 and the applicator roller 728, is
effectively prevented or at least controlled such that engagement
of the applicator roller 728 with the palletized load 652 is
maintained. The provision of the plurality of holes or apertures
736 within the side edge portion of the bottom support plate 686
permits one to adjust the effective spring biasing force of the
coil spring 740.
[0078] Continuing further, and with reference being made to FIG.
28, it will be appreciated that as the applicator roller 728 makes
contact with the palletized load 652, the movement of the
applicator roller 728 along the side wall of the palletized load
will cause the applicator roller to rotate. This rotation of the
applicator roller 728 will cause the adhesive dots 722 to be
applied to the palletized load 652, and at the same time will cause
the adhesive dot supply roll 716 to rotate. The adhesive dot supply
roll 716 is operatively connected to the take-up roll or reel 720
by means of a suitable connector band 744 such that the take-up
roll or reel 720 is rotated in unison with the adhesive dot supply
roll 716. With continued reference being made to FIG. 28, the
purpose of the idler roller 732 is that when the applicator roller
728 is rolling along the side wall of the palletized load 652, a
space between individual cartons or boxes on the palletized load
652 may be encountered. For example, with reference being made to
FIG. 20, two cartons or boxes 746,748 are noted, and there is a
small space 750 defined between the cartons or boxes 746,748. In
order to effectively prevent the applicator roller 728 from
entering the space 750, or to become trapped in such space, the
idler roller 732 is engaged with a side wall portion of, for
example, the box or carton 748 so as to prevent the applicator
roller 728 from entering the space 750 to any large extent.
[0079] Obviously, many variations and modifications of the present
invention are possible in light of the above teachings. It is
therefore to be understood that within the scope of the appended
claims, the present invention may be practiced otherwise than as
specifically described herein.
* * * * *