US20050150188A1 - Modular shrink-wrap machine - Google Patents
Modular shrink-wrap machine Download PDFInfo
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- US20050150188A1 US20050150188A1 US11/028,977 US2897705A US2005150188A1 US 20050150188 A1 US20050150188 A1 US 20050150188A1 US 2897705 A US2897705 A US 2897705A US 2005150188 A1 US2005150188 A1 US 2005150188A1
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- United States
- Prior art keywords
- canceled
- machine
- products
- shrink
- film
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B59/00—Arrangements to enable machines to handle articles of different sizes, to produce packages of different sizes, to vary the contents of packages, to handle different types of packaging material, or to give access for cleaning or maintenance purposes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B53/00—Shrinking wrappers, containers, or container covers during or after packaging
- B65B53/02—Shrinking wrappers, containers, or container covers during or after packaging by heat
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B57/00—Automatic control, checking, warning, or safety devices
- B65B57/10—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged
- B65B57/12—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged and operating to control, or stop, the feed of wrapping materials, containers, or packages
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B59/00—Arrangements to enable machines to handle articles of different sizes, to produce packages of different sizes, to vary the contents of packages, to handle different types of packaging material, or to give access for cleaning or maintenance purposes
- B65B59/001—Arrangements to enable adjustments related to the product to be packaged
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B65/00—Details peculiar to packaging machines and not otherwise provided for; Arrangements of such details
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B9/00—Enclosing successive articles, or quantities of material, e.g. liquids or semiliquids, in flat, folded, or tubular webs of flexible sheet material; Subdividing filled flexible tubes to form packages
- B65B9/06—Enclosing successive articles, or quantities of material, in a longitudinally-folded web, or in a web folded into a tube about the articles or quantities of material placed upon it
- B65B9/067—Enclosing successive articles, or quantities of material, in a longitudinally-folded web, or in a web folded into a tube about the articles or quantities of material placed upon it the web advancing continuously
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B2210/00—Specific aspects of the packaging machine
- B65B2210/04—Customised on demand packaging by determining a specific characteristic, e.g. shape or height, of articles or material to be packaged and selecting, creating or adapting a packaging accordingly, e.g. making a carton starting from web material
Definitions
- the invention relates to apparatus for wrapping products with heat shrinkable film and, more particularly, to a high-speed modular shrink-wrap system for individually wrapping products sequentially with shrink-wrap material.
- Co-assigned Stork U.S. Pat. No. 5,956,931 shows an apparatus for wrapping products in which products are provided to a delivery conveyor, wrapped in a tube of heat-sealable material, and to a sealing station wherein sealing heads are brought into and out of engagement with a tube to cut and seal the plastic, i.e. film material forming the tube.
- the products, which are delivered as wrapped packages onto an exit conveyor, proceed into a heat-shrink station for final processing and discharge.
- That patent describes an arrangement for positioning and movement of the sealing heads which can be readily adjusted, as by operator input. Movement of the head is detected by an electric eye which determines relative dimensions of the product for initiating appropriate movement of the sealing head or heads.
- installation may require the operator to be positioned on either side of the machine relative to the direction of movement of products through the machine.
- the location of an operator may depend upon assembly line constraints. For example, in replacement of existing equipment, a new machine may require that the operator stand on one side which is the same as in operating a previous machine. Further, in some installations, a single operator may be desirably positioned between two product wrapping lines so that, for example, product on one line will move from right to left from the operator's perspective, but when the operator faces in an opposite direction, will move from left to right. Therefore, it is desirable that machines of this character be ambidextrous in character, if possible, so as to allow an operator to be located on either side of the machine.
- a selectively reconfigurable shrink-wrap machine for use with a loading device for individually wrapping products sequentially with shrink-wrap material.
- the loading device delivers products in sequence to the machine for wrapping with shrink-wrap material.
- the shrink-wrap machine includes a sensor associated with the loading device for sensing product position on the loading device.
- a film supply presents a roll of shrink-wrap material that is associated with a wrapping station at which products are wrapped with film material from the film supply.
- a first conveyor carries products wrapped in the film material between the wrapping station and a film sealing and cutting apparatus. Moreover, the first conveyor is driven to deliver products sequentially in synchronized velocity with the loading device in response to signals generated by the sensor.
- the film sealing and cutting apparatus has an upper head and a lower head. At least one the heads is driven for movement into and out of engagement with the other head between adjacent film wrapped products received by the first conveyor for effecting a seal between adjacent products. Moreover, the upper head and the lower head are each maintained at a fixed angle of orientation relative to a direction of movement of products along the first conveyor.
- a second conveyor is disposed adjacent the film sealing and cutting apparatus for receiving wrapped products sequentially from the sealing and cutting apparatus. As products are delivered by the first conveyor, the film sealing and cutting apparatus sequentially seals and cuts the products.
- a microprocessor-driven control system has a touch sensitive viewing and controlling means for prompting and receiving operator response for controlling operation of the shrink-wrap machine.
- the control system has microprocessor circuits selectively programmed for control of at least one of a plurality of different possible wrapping stations or modes of operation.
- FIG. 1 is a perspective view of apparatus for automatically wrapping products in thermoplastic film, in accordance with and embodying of the present invention.
- FIG. 2 is a similar view with certain panels removed for clarity.
- FIG. 3 is a simplified plan view of the apparatus of FIG. 1 .
- FIG. 3A is an enlarged plan view of the loading conveyor of FIG. 3 .
- FIG. 4 is a perspective view of heat sealing and cutting apparatus and drive components used in the apparatus of FIG. 1 .
- FIG. 5 is a perspective view of a subassembly of FIG. 4 .
- FIG. 5A is a side view of a gear of FIG. 5 .
- FIG. 5B is a further side view of a gear of FIG. 5 of a gear rotation of 180 degrees.
- FIG. 6A is a simplified illustration of sealing and cutting operations of the apparatus.
- FIG. 6B is a further illustration of a sequence in the cutting and sealing operations.
- FIG. 6C is still further sequence in a sealing and cutting operation.
- FIG. 6D is a further illustration following a cutting operation.
- FIG. 7 is a perspective view of film supply apparatus of the invention.
- FIG. 8 is an exploded view of a film supply spindle and spindle positioning components of the apparatus of FIG. 7 .
- FIG. 9 is a perspective view of a film quantity sensing apparatus.
- FIG. 10 is a block diagram of software modules of the software of which operates the apparatus.
- FIG. 11 is a perspective view of products along the vacuum conveyor.
- FIG. 11A is an end view illustrating a product wrapped in film material having a static seal.
- FIG. 11B is an end view illustrating a product wrapped in film material having a fin seal.
- FIG. 12 is a perspective view of apparatus with further panels removed.
- FIG. 13 is a perspective view of products interspersed with missing products along the vacuum conveyor.
- FIG. 14 is a simplified illustration of sealing and cutting operations of the apparatus with missing products interspersed.
- shrink-wrap machine 30 comprises a support frame 32 which supports a loading conveyor 34 .
- a wrapping station 40 is disposed adjacent support frame 32 .
- a film dispensing station 36 is disposed adjacent wrapping station 40 .
- a support frame 38 secures a vacuum conveyor 42 which is disposed adjacent film dispensing station 36 .
- Support frame 38 secures exit conveyor 50 which is disposed a predetermined distance from vacuum conveyor 42 with a film sealing and cutting apparatus 44 interposed therebetween.
- a guard frame 46 which encloses film sealing and cutting apparatus 44 , pivotally secures touch sensitive monitor 48 .
- loading conveyor 34 comprises a support frame 32 for securing a slotted belt 54 which proceeds in a longitudinal direction along loading conveyor 34 beneath loading surface 35 .
- a longitudinal slot 37 is formed in loading surface 35 , exposing belt 54 .
- opposing guides 52 which run longitudinally along loading surface 35 , may be selectively separated to correspond to the width of products 58 proceeding longitudinally along loading conveyor 34 .
- multiple equidistantly spaced product propelling means 56 are inserted in slotted belt 54 .
- Slotted belt 54 is driven by a motorized means 60 , preferably a permanent magnet D.C. motor.
- a sensor 62 (not shown but represented by dashed line in FIG. 1 ) is disposed along belt 54 for sensing the position of lugs 56 as lugs 56 travel past sensor 62 .
- sensor 62 generates electrical signals in accordance with the Hall Effect. Using these generated electric signals permits shrink-wrap machine 30 to synchronize belt speeds and effect precise control of product 58 position during operation.
- Film dispensing station 36 is comprised of a pair of vertical support members 64 which are securely connected to support frame 38 by brackets 66 . Further, a proximally positioned vertical support member 64 is securely connected to an open support end 68 having a pair of pivoting members 67 which are prevented from pivoting by pins 69 . A distally positioned vertical support member 64 is securely connected to a closed support end 70 . A spindle member 72 is disposed between open support end 68 and closed support end 70 for carrying a roll of film material 92 thereon. Access for removal of a roll of film material is effected by actuating pin 69 whereby member 67 pivots to position 71 . As is shown in FIG. 7 , film dispensing station 36 may accommodate two separate rolls of film material 92 .
- spindle member 72 is further disclosed.
- Spindle member 72 comprises a central shaft 94 which further includes a distal end 95 and a proximal end 96 .
- Distal end 95 is nonrotatably attached to closed support end 70 .
- An outer shaft 97 which further includes an inside surface 99 and an outside surface 103 slides over central shaft 94 and is maintained in concentric rotational proximity along longitudinal axis 101 by multiple bearings 98 .
- a pair of locking collars 100 are slidably fitted upon opposing ends of outer shaft 97 for securing a roll of film material 92 therebetween.
- central shaft 94 includes a threaded portion 102 along its proximal end 96 .
- Adjustment collar 104 includes a proximal segment 107 having a knurled gripping surface 105 and a distal segment 109 having an outside surface 111 . Adjustment collar 104 further includes a knurled gripping surface 105 for ready operator adjustment. Additionally, a ring 108 having an inside surface 110 and an outside surface 113 is fitted upon outside surface 111 establishing a press fit therebetween.
- adjustment collar 104 is rotated about longitudinal axis 101 after being placed in threaded engagement with central shaft 94 , as adjustment collar 104 proceeds in either direction along longitudinal axis 101 , outer shaft 97 likewise proceeds along longitudinal axis 101 due to the integral construction between adjustment collar 104 and outer shaft 97 .
- locking nut 112 has a knurled gripping surface 116 and an internally threaded aperture 114 that may be placed in threaded engagement with threaded portion 102 .
- knurled gripping surface 116 and rotating locking nut 112 along longitudinal axis 101 in a direction toward adjustment collar 104 until there is secure contact therebetween locking nut 112 will prevent adjustment collar 104 from rotating with respect to central shaft 94 . It is appreciated that this arrangement permits an operator to move a film roll 92 in either direction along longitudinal axis 101 by rotating adjustment collar 104 which is in threaded engagement with central shaft 94 in a desired direction along longitudinal axis 101 while the shrink-wrap machine 30 of the present invention is in operation.
- Retarding device 74 includes an elongated member 76 having a proximal end 78 and recessed region 80 immediately adjacent proximal end 78 . Further, distal end 82 is securely connected in closed support end 70 . Retarding device 74 is configured to receive a flexible retarding member 84 .
- Flexible retarding member 84 includes a first loop 86 which is pivotally engaged with recessed region 80 of elongated member 76 and a second loop 88 that secures a weight 90 for maintaining retarding member 84 in position.
- flexible retarding member 84 extends over and around the periphery of a roll of film material 92 , providing non-marring frictional resistance to rotation of a roll of film material 92 about longitudinal axis 83 , 89 while dispensing film material 92 about products 58 .
- the frictional resistance that is generated between inner surface 85 and the periphery of a roll of film material 92 is not specifically shown, as film material 92 is depicted in phantom lines for purposes of clarity. It is appreciated that this frictional force will tend to minimize the amount of unrestricted dispensing of film material 92 when wrapping operation is halted.
- indexing device 118 is further illustrated.
- Index device 118 includes an elongated portion 120 having a proximal end 122 and a distal end 124 .
- elongated portion 120 protrudes through closed support end 70 so that elongated portion 120 may rotate about its longitudinal axis 126 .
- a first sensing member 128 extends radially from proximal end 122
- second sensing member 130 extends radially from distal end 124 .
- First sensing member 128 and second sensing member 130 are situated in a predetermined angular relationship with each other and with respect to longitudinal axis 126 .
- a first curved slot 132 and a second curved slot 134 is formed in closed support end 70 .
- a first sensing device 136 and a second sensing device 138 are disposed in first curved slot 132 and second curved slot 134 , respectively for sensing a predetermined extent of depletion and total depletion, respectively, of a roll of film material 92 .
- a second set or pair of curved slots and sensing devices are provided as film dispensing station 36 is configured to secure two rolls of film material 92 .
- Sensing devices 136 , 138 operate in accordance with the Hall Effect and send electrical signals when second sensing member 130 passes in sufficiently proximately therewith.
- an operator warning device (not shown) may be provided for warning an operator of a predetermined extent of depletion or total depletion, respectively, of a roll of film material 92 .
- first sensing member 128 rests atop outer surface 87 of flexible retarding member 84 for monitoring the amount of shrink-wrap material 92 remaining on a roll.
- Second sensing member 130 is pivotally adjacent first and second sensing devices 136 , 138 .
- first sensing member 128 maintains an offset tangential contact along the radius of the roll. This offset is due to the thickness of the flexible retarding member 84 as first sensing member 128 rotates about longitudinal axis 126 of the elongated portion 120 .
- second sensing member 130 rotates about longitudinal axis 128 .
- second sensing member 130 achieves such proximity with first sensing device 128 as to activate first sensing device 136 and thereby alert an operator of a predetermined level of depletion of film material 92 from a film roll.
- second sensing member 130 Upon the roll being totally expended of film material 92 , second sensing member 130 achieves such proximity with second sensing device 138 as to activate second sensing device 138 thereby alerting the operator that film material 92 of a film roll has been totally expended.
- wrapping station 40 is disposed adjacent loading conveyor 34 for receiving products propelled by lug 56 .
- Wrapping station 40 is well known in the art, using film material 92 for wrapping product 58 by directing film material 92 from film dispensing station 36 to closely wrap products 58 peripherally along their longitudinal axes within a continuous tube 93 of film material 92 so that tube 93 is formed therearound product 58 ( FIG. 11 ).
- FIGS. 11A an overlapping region 81 is formed between opposed ends 79 of film material 92 .
- a sealing device 41 ( FIG. 1 ) disposed adjacent wrapping station 40 establishes a continuous seam 77 along overlapping region 81 .
- wrapping station 40 establishes a static seal.
- different types of wrapping stations are used to form different kinds of seals ( FIGS. 11A, 11B ), which are also known in the art, shrink-wrap machine 30 of the present invention provides for modular wrapping stations 40 which may be selectively installed according to a customer's preference.
- vacuum conveyor 42 is disposed adjacent film dispensing station 36 and carries film tube 93 which is very closely wrapped around product 58 . Further, by generating a partial pressure along vacuum conveyor 42 , products 58 are sequentially conveyed without their being shifted from the position at which product 58 first makes contact with vacuum conveyor 42 . Moreover, movement along vacuum conveyor 42 is maintained in synchronization with loading conveyor 34 because the motorized means, preferably a stepper motor, driving vacuum conveyor 42 receives electrical signals generated by sensor 62 , which is most preferably a Hall Effect sensor, and which produces a voltage each time a lug 56 passes sensor 62 (not shown). This arrangement permits uniform spacing 150 between adjacent products 58 travelling along the longitudinal axis of vacuum conveyor 42 .
- film sealing and cutting apparatus 44 is disposed at a predetermined fixed distance from vacuum conveyor 42 . Additionally, apparatus 44 is configured to move into and out of engagement between adjacent film wrapped products 58 . In making these movements, apparatus 44 places a transverse cut 91 or end seal between adjacent sequentially presented products 58 before passing newly separated products 58 , or packages 59 ( FIGS. 6A, 6D ), onto exit conveyor 43 .
- upper gear 142 is rotatably connected to frame structure 140 about center axis 144 .
- fixed central gear 146 is non-rotatably secured along center axis 144 .
- First eccentric gear 148 which is carried by uppergear 142 meshes with central gear 146 that further meshes with second eccentric gear 150 which is also carried by upper gear 142 .
- second eccentric gear 150 rotates about eccentric axis 152 .
- first eccentric gear 148 is urged into rotation by meshing engagement with central gear 146 .
- second eccentric gear 150 which rotates about eccentric axis 152 is placed in opposing rotation with respect to upper gear 142 .
- second eccentric gear 150 although eccentrically rotating about center axis 144 , rotates about eccentric axis 152 so that lower gear 162 is maintained in alignment with vertical axis 200 .
- FIGS. 5 A and 6 A- 6 D rotation of second eccentric gear 150 about eccentric axis 152 is best explained by use of reference point 153 .
- Reference point 153 in FIG. 5A appears on the upper periphery of second eccentric gear 150 in-line with vertical axis 200 .
- reference point 153 continues to appear at the top vertical position of second eccentric gear 150 in-line with vertical axis 200 . Therefore, as shown on FIGS. 5A and 5B and 6 A- 6 B, while lower gear 162 completes a rotation cycle about center axis 170 , second eccentric gear 150 rotates about eccentric axis 172 so that upper head 156 remains parallel to vertical axis 200 .
- upper head 156 includes a body 154 having a pair of in-line apertures 155 on opposing ends of body 154 . Apertures 155 accept opposing shafts 157 which extend from second eccentric gears 150 for rotational orientation with respect to eccentric axis 152 . Upper head 156 further includes a cutter portion 158 disposed between a pair of film clamps 160 . Cutter portion 158 and film clamps 160 are slidably movable along pins 161 . Further, multiple hat-shaped structures 163 are biased against multiple springs 159 to force both cutter portion 158 and film clamps 160 in an extended position.
- lower gear 162 includes a fixed central gear 146 which is non-rotatably mounted to frame structure 140 , although lower gear 162 may rotate about center axis 170 .
- first eccentric gear 148 meshes with central gear 146 and second eccentric gear 150 likewise meshes with first eccentric gear 148 .
- Second eccentric gear 150 rotates about eccentric axis 172 . Therefore, as lower gear 162 rotates about center axis 170 , first eccentric gear 148 is urged into rotation by meshing engagement with central gear 146 . Additionally, second eccentric gear 150 which rotates about eccentric axis 172 is placed in opposing rotation with respect to lower gear 162 .
- second eccentric gear 150 although eccentrically rotating about center axis 170 , rotates about eccentric axis 172 so that lower gear 162 is maintained in alignment with vertical axis 200 .
- rotation of second eccentric gear 150 about eccentric axis 152 is best explained by use of reference point 153 .
- Reference point 153 in FIG. 5A appears on the upper periphery of second eccentric gear 150 in-line with vertical axis 200 .
- reference point 153 continues to appear at the top vertical position of second eccentric gear 150 in-line with vertical axis 200 . Therefore, as shown on FIGS. 5A and 5B and 6 A- 6 B, while upper gear 142 completes a rotation cycle about center axis 144 , second eccentric gear 150 rotates about eccentric axis 152 so that upper head 156 remains parallel to vertical axis 200 .
- lower head 164 includes a body 174 having a pair of in-line apertures 176 on opposing ends of body 174 .
- Apertures 176 accept opposing shafts 151 which extend from second eccentric gears 150 for rotational orientation with respect to eccentric axis 172 .
- Body 174 further includes multiple apertures 178 for accepting in sliding contact therein pins 180 which protrude from platen portion 182 .
- Springs 184 are fitted upon pins 180 prior to insertion into body 174 and bias body 174 in a direction away from platen head portion 182 , that is, in a direction along the longitudinal axes of pins 180 .
- a pair of serpentine belts 186 mesh about the peripheries of upper gear 142 and lower gear 162 .
- Each serpentine belt 186 meshes an outer pulley 188 secured in non-rotating orientation with respect to a shaft 192 , with an inner pulley 190 being disposed between outer pulleys 188 along shaft 192 .
- Shaft 192 is journaled to frame structure 140 .
- a belt 194 engages inner pulley 190 and pulley 196 of motorized means 198 , preferably a servo motor.
- upper gear 142 and lower gear 162 are being driven in opposing rotational directions about their respective center axes 144 , 170 .
- upper head 156 is carried having a fixed angle of orientation, preferably with vertical axis 200
- lower head 164 is likewise carried having a fixed angle of orientation, preferably in alignment with vertical axis 200 .
- FIGS. 6A-6D it is appreciated that upper head 156 and lower head 164 are maintained synchronously and mutually toward and away from each other about a predetermined path.
- cutter portion 158 of upper head 156 and platen head portion 182 of lower head 164 are engaged once for every full rotation of upper gear 142 and lower gear 162 .
- upper head 156 and the lower head 164 rotate in and out of engagement while maintaining a fixed angle of orientation, preferably in-line with a vertical axis 200 .
- cutter portion 158 and the platen head portion 182 each maintain a predetermined path, preferably circular, due to the epicyclical arrangement with gears 146 , 148 and 150 .
- apparatus 44 most efficiently performs its task by engaging film material along a product's mid-point axis 202 ( FIG. 6A ).
- a means to vertically adjust the entire apparatus 44 is required. This is effected, by use of a motorized means 218 , such as a permanent D.C. motor.
- Motorized means 218 is secured to support frame 38 for driving a chain belt 220 which engages a gear 222 .
- Gear 222 is secured to a proximal end 226 of a shaft 224 with a mounting means 228 securing to a distal end 229 of shaft 224 .
- bevel gears 230 are disposed along shaft 224 and at proximal ends 232 of threaded shafts 234 .
- Shafts 234 are threadedly engaged with blocks 236 of apparatus 44 .
- motorized means 218 drives gear 222 , which imparts rotation to shaft 222 that further rotates bevel gears 230 disposed along shaft 224 .
- bevel gears 230 at proximal ends 232 of threaded shafts 234 being meshed with bevel gears 230 along shaft 224 , impart rotation about threaded shafts 234 .
- apparatus 44 is raised or lowered until the desired height is reached.
- exit conveyor 50 is disposed in close proximity with apparatus 44 and vacuum conveyor 42 .
- Exit conveyor 50 receives sequentially delivered products 58 from vacuum conveyor 42 and apparatus 44 after a transverse seal 91 has been placed between each adjacent product 58 .
- a motorized means 236 FIG. 12 , preferably a permanent magnet D.C. motor, is utilized to carry products 58 sequentially therefrom in a predetermined relationship with respect to loading conveyor 34 .
- the operator may find it desirable to drive exit conveyor 50 at a lower speed than vacuum conveyor 42 is driven.
- a touch sensitive monitor 48 includes an arm 49 which is pivotally engaged with guard frame 46 .
- film dispensing station 36 includes an open support end 68 from which an operator 47 may either load or unload a roll of film material 92 .
- An operator 47 may grasp monitor 48 and pull monitor 48 towards the operator so that arm 49 pivots about guard frame 46 , thus moving monitor 48 on the same side of machine 30 as open support 68 of film dispensing station 36 .
- operator 47 may rotate monitor 48 about its base 51 if desired.
- Flow diagram 250 includes the following modules which are contained in a box and includes set-up program 252 , which after a reference button is pushed (Step 253 ), proceeds into homing program 254 that thereafter proceeds into either main program 256 or to PLC program 258 .
- a fault program 260 continuously runs in the background but is not specifically part of the flow diagram.
- Set-up program 252 includes initializing variables for operation of the machine and include provision for the operator to:
- set-up program 252 sets the scaling for the servo axis which includes a predetermined number of counts per degree rotation of sealing and cutting apparatus 44 , and vacuum conveyor 42 which additionally has a predetermined number of counts per unit displacement along the longitudinal direction of vacuum conveyor 42 .
- This scaling permits shrink-wrap machine 30 to extremely accurately calculate the position of products 58 as they proceed down vacuum conveyor 42 and reach apparatus 44 .
- set-up program 252 sets error checking bits, the violation of which may terminate operation of shrink-wrap machine 30 .
- Homing program 254 must be initially invoked by depressing reference button 253 . Once reference button 253 is depressed, homing program 254 finds the film clamping zone 262 ( FIGS. 6B, 6C ). Film clamping zone 262 refers to the angular range in which upper head 156 and lower head 164 are in contact with film material 92 between adjacent products. Additionally, homing program 254 calculates the top dead center position (not shown), wherein upper head 156 is located at its uppermost position in its movement cycle and lower head 164 is positioned at its lowest vertical position with respect to its cycle of movement. Therefore, the top bid center position corresponds to the tallest product that the shrink-wrap machine can accommodate.
- homing program 254 also references the ceiling height to which motorized means 218 must move apparatus 44 so that upper head 156 and lower head 164 are engaged at a height that corresponds to one-half of the height of an incoming product down the vacuum conveyor 42 .
- Main program 256 controls the normal operation of all motor positions or axes.
- main program 256 calculates the ratios between web matching and cam following.
- Web matching refers to matching the speed of product 58 along vacuum conveyor 42 with the horizontal speed of apparatus 44 while upper head 156 and lower head 164 are in the film clamping zone.
- Cam following refers to the 360 degree rotational speed motion of upper head 156 and lower head 164 .
- PLC program 258 monitors all machine input and output stations while continuously scanning. Reference button 253 is pushed only when initially turning on the machine and is not again required to be pressed until after a machine is shut off, it is only during the initial turn-on period.
- Full program 260 monitors all machine fault bits continuously as it is a program that runs in the background.
- Fault program 262 monitors commands based on error bit detection, taking predetermined steps to address any particular error. Some error bits can be operator configured such as electing or not electing to activate an alarm when a film roll is expended.
- Set-up program 252 permits an operator great flexibility and ease of operation by permitting the operator to input dimensions for different packages to be processed without the operator having to otherwise physically make any other alterations to the shrink-wrap machine.
- machine 30 After operator 47 has turned on the machine 30 and has made selections on touch sensitive monitor 48 , machine 30 indicates on monitor 48 the proper spacing for lugs 56 along loading conveyor 34 . Additionally, the correct wrapping station 40 must be installed into machine 30 . Further, at least one roll of film material 92 must be loaded onto film dispensing station 36 and threaded through wrapping station 40 before the wrapping process for products 58 may commence. Products 58 are placed on loading conveyor 34 and properly spaced as shown in FIG. 3A and sequentially propelled into wrapping station 40 by lugs 56 .
- Products 58 then begin to pass in sequential procession through wrapping station 40 , wherein each product is closely wrapped peripherally about its longitudinal axis within a continuous tube of film material 93 formed therearound.
- Opposing ends of shrink-wrap material 92 wrap products 58 , forming regions of overlapping shrink-wrap material 81 along the products' longitudinal axes.
- a sealing device in association with the modular wrapping station 40 (not shown) establishes a continuous seam 77 along the region of overlapping shrink-wrap material 81 . It can be appreciated by one skilled in the art that wrapping station 40 may be of multiple configurations. Therefore, the region of overlapping material 81 may be differently configured as would be the sealing arrangement required to establish the seam 77 between overlapping material 81 .
- products 58 proceeding along vacuum conveyor 42 are snugly wrapped in a tube 93 , and move with the film wrap material at a first predetermined spacing 204 therebetween. Products 58 further proceed along vacuum conveyor 42 toward film sealing and cutting apparatus 44 for receiving a transverse seal 91 between each adjacently positioned product 58 .
- package A has already passed film sealing and cutting apparatus 44 , is on exit conveyor 43 and ready for delivery into heat chamber (not shown).
- the term “package” is applied to wrapped products that have received transverse seals of film material in front of its leading end and after its trailing end.
- Product B has received a transverse seal 91 in front of its leading end 208 with cutter portion 158 and platen head portion 182 rotating in position to place a transverse seal 91 between trailing end 210 of product B and leading end 212 of product C.
- the spacing between adjacent products such as between product C and product D which initially is first predetermined spacing 204 , may be revised or reduced such as between product B and C to a second predetermined spacing 206 .
- This reduced spacing may be desirable for a taller product 58 . Therefore, assuming the product 58 to be tall, to effect the shorter second predetermined spacing 206 , exit conveyor 43 must operate at a slightly slower speed than that of vacuum conveyor 42 .
- the speed of product B becomes slightly less with respect to product C which is still on vacuum conveyor 42 , thereby producing second predetermined spacing 206 between product B and product C.
- This reduced spacing produces a condition of reduced tension of film tube 93 which permit cutter portion 158 and platen head portion 182 to effect an improved transverse seal 91 between product B and product C.
- cutting portion 158 and platen head portion 182 first come into contact with film tube 93 .
- This range of contact between cutter portion 158 and platen head portion 182 is referred to as the film clamping zone 262 which extends 20 degrees to either side of the vertical axis 200 .
- maintaining upper head 156 and lower head 164 and fixed relationship therebetween, preferably along vertical axis 200 permits an improved seal due to equal tension of film tube 93 between product B and product C.
- cutting head 158 and platen portion 182 remain in contact with each other, and have effected a transverse seal 91 between product B and product C. Further, FIG.
- 6D shows cutter portion 158 and platen head portion 182 movement out of contact from between product B and product C, transverse seal 91 having been formed therebetween. As is appreciated, this process for establishing transverse seal 91 is sequentially repeated for product C, B and so on.
- sensor 62 senses a product propelling means 56 , preferably lugs, not the product 58 itself.
- sensor 62 generates signals corresponding to an anticipated product 58 position, irrespective of the existence of a product 58 in that position.
- this “missing product” condition is illustrated.
- an additional distinction between products is shown by reference characters character A, B, C or D within the product box or if there is no product, i.e., a missing product, the character is circled.
- FIG. 13 wrapped in continuous film material tube 93 , products B and D appear interposed with missing products A and C.
- transverse seal 91 it is shown that missing product A and product B have been separated by transverse seal 91 and missing product C has received a first transverse seal 91 . Therefore, without operator intervention, and so long as sufficient film material 92 remains on film dispensing station 36 , machine 30 operates normally. That is, film sealing and cutting apparatus 44 will continue to form transverse seals 91 in film tube 93 between anticipated positions of adjacent products 58 .
- a method for controlling a shrink-wrap machine comprises:
Abstract
Selectively reconfigurable shrink-wrap machine (30) for use with a loading device (34) for individually wrapping products (58) sequentially with shrink-wrap material (92) as delivered in sequence to the machine. It includes a sensor (62) sensing product position on the loading device. Shrink-wrap material is delivered from a roll at a wrapping station (40). A first conveyor (42) carries wrapped products between the wrapping station and a film sealing and cutting apparatus (44). First conveyor delivers products sequentially in synchronized velocity with the loading device in response to sensor signals. Film sealing and cutting apparatus has upper and lower heads (156, 164), at least one of which is driven into and out of engagement with the other between adjacent wrapped products received by the first conveyor for effecting a sealed cut between them. Heads are each maintained at a fixed angle of orientation. A second conveyor (43) receives wrapped products sequentially from the sealing and cutting apparatus. A microprocessor-driven touch screen (48) and a method controls the shrink-wrap machine and is described.
Description
- This application is based upon and claims priority of United States Provisional Patent Application entitled Modular Shrink-Wrap Machine, Ser. No. 60/244,360, filed 30 Oct. 2000.
- Field of the Invention
- The invention relates to apparatus for wrapping products with heat shrinkable film and, more particularly, to a high-speed modular shrink-wrap system for individually wrapping products sequentially with shrink-wrap material.
- Many arrangements have been known or proposed for wrapping of products with heat-sealable or heat-shrinkable film material. Co-assigned Stork U.S. Pat. No. 5,956,931 shows an apparatus for wrapping products in which products are provided to a delivery conveyor, wrapped in a tube of heat-sealable material, and to a sealing station wherein sealing heads are brought into and out of engagement with a tube to cut and seal the plastic, i.e. film material forming the tube. The products, which are delivered as wrapped packages onto an exit conveyor, proceed into a heat-shrink station for final processing and discharge. That patent describes an arrangement for positioning and movement of the sealing heads which can be readily adjusted, as by operator input. Movement of the head is detected by an electric eye which determines relative dimensions of the product for initiating appropriate movement of the sealing head or heads.
- In addition, it has also been proposed to use computer software programs for controlling the operation of such shrink-wrap machines wherein the software can provide operator input to define movement of sealing heads and other characteristics appropriate to the type of seal, such fin seal, static seal, lap seal and other types of seals, using machinery of this type.
- It has also been proposed to use vacuum conveyors for maintaining a package into tractive adherence, while wrapped in a tube sealing material, while the product is brought into a sealing position.
- It has been proposed to use orbitally reciprocating sealing heads or apparatus for sealing and severing each film-wrapped package from each other, including with continuous motion of the product on such a vacuum conveyor as it moves through the sealing section and into an exit region and before heat-shrinking of the film material about the wrapped product.
- However, these prior art arrangements have not fully achieved the speed and throughput or ease of adjustment and change desired by customers. It has been found by the present inventors that speed and throughput can be improved by more accurate sensing of the position of products as they move from a delivery conveyor into a heat sealing station, and by precisely controlling the movement of sealing heads as they are brought into and out of engagement with a tube of film material that wraps a product.
- One of the challenges which face manufacturers of this type of equipment is the need for the equipment to accommodate many different types of products, widths, heights and shapes, as are dictated by the uses to which the machines will be put. Heretofore, prior art packaging systems and film-wrapping apparatus have not provided to the full extent desired accommodation to these various needs which will allow changes to be rapidly and effectively carried out by an operator by simple control input, as compared with time-consuming and difficult mechanical adjustments of features. It is desirable to provide equipment of this scope with a high degree of both mechanical and electrical changeability for providing modular characteristics, by which both mechanical and electrical features can be changed by the substitution of modules or by software-implemented changes under the control of an operator.
- In apparatus of this type, installation may require the operator to be positioned on either side of the machine relative to the direction of movement of products through the machine. The location of an operator may depend upon assembly line constraints. For example, in replacement of existing equipment, a new machine may require that the operator stand on one side which is the same as in operating a previous machine. Further, in some installations, a single operator may be desirably positioned between two product wrapping lines so that, for example, product on one line will move from right to left from the operator's perspective, but when the operator faces in an opposite direction, will move from left to right. Therefore, it is desirable that machines of this character be ambidextrous in character, if possible, so as to allow an operator to be located on either side of the machine.
- Among the several objects, features and advantages of the present invention may be noted the provision of automatic packaging systems for wrapping products with film material, forming a preselected type of package seal and for separating film material wrapped about the product so as to provide individually wrapped packages, which:
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- achieves extremely high speed and throughput;
- during operation is capable of sensing precisely the position of packages entering the machine;
- when sensing the position of packages uses electronic, microprocessor-controlled sensing of the position of products to quickly and precisely bring cutting and sealing heads into and but of engagement with products;
- operates by wrapping, sealing and separating the wrapped packages by using smooth, synchronized operation of sealing and cutting heads in such a way as to avoid wasted, lost motion;
- allows ready changeability of both mechanical and electronic features by employing modular components;
- allows quick operator reconfiguration in a facile manner without costly set-up or time-consuming mechanical adjustments;
- during change and adjustment allows software input to be quickly and effectively made by display screen input;
- allows processor-implemented changes to be carried out electronically rather than mechanically;
- is capable of ambidextrous use to permit an operator to be located on either side of the collection of movement of packages through the apparatus;
- allows an operator input device to be reoriented to either side of the machine; and
- allows rapid changing or reloading of film material to either side of the machine, being readily configurable for that purpose.
- Briefly, a selectively reconfigurable shrink-wrap machine for use with a loading device for individually wrapping products sequentially with shrink-wrap material. The loading device delivers products in sequence to the machine for wrapping with shrink-wrap material. Further, the shrink-wrap machine includes a sensor associated with the loading device for sensing product position on the loading device. Additionally, a film supply presents a roll of shrink-wrap material that is associated with a wrapping station at which products are wrapped with film material from the film supply.
- A first conveyor carries products wrapped in the film material between the wrapping station and a film sealing and cutting apparatus. Moreover, the first conveyor is driven to deliver products sequentially in synchronized velocity with the loading device in response to signals generated by the sensor.
- The film sealing and cutting apparatus has an upper head and a lower head. At least one the heads is driven for movement into and out of engagement with the other head between adjacent film wrapped products received by the first conveyor for effecting a seal between adjacent products. Moreover, the upper head and the lower head are each maintained at a fixed angle of orientation relative to a direction of movement of products along the first conveyor. A second conveyor is disposed adjacent the film sealing and cutting apparatus for receiving wrapped products sequentially from the sealing and cutting apparatus. As products are delivered by the first conveyor, the film sealing and cutting apparatus sequentially seals and cuts the products.
- A microprocessor-driven control system has a touch sensitive viewing and controlling means for prompting and receiving operator response for controlling operation of the shrink-wrap machine. The control system has microprocessor circuits selectively programmed for control of at least one of a plurality of different possible wrapping stations or modes of operation.
- Other objects, features and advantages will be in part apparent and in part pointed hereinbelow.
-
FIG. 1 is a perspective view of apparatus for automatically wrapping products in thermoplastic film, in accordance with and embodying of the present invention. -
FIG. 2 is a similar view with certain panels removed for clarity. -
FIG. 3 is a simplified plan view of the apparatus ofFIG. 1 . -
FIG. 3A is an enlarged plan view of the loading conveyor ofFIG. 3 . -
FIG. 4 is a perspective view of heat sealing and cutting apparatus and drive components used in the apparatus ofFIG. 1 . -
FIG. 5 is a perspective view of a subassembly ofFIG. 4 . -
FIG. 5A is a side view of a gear ofFIG. 5 . -
FIG. 5B is a further side view of a gear ofFIG. 5 of a gear rotation of 180 degrees. -
FIG. 6A is a simplified illustration of sealing and cutting operations of the apparatus. -
FIG. 6B is a further illustration of a sequence in the cutting and sealing operations. -
FIG. 6C is still further sequence in a sealing and cutting operation. -
FIG. 6D is a further illustration following a cutting operation. -
FIG. 7 is a perspective view of film supply apparatus of the invention. -
FIG. 8 is an exploded view of a film supply spindle and spindle positioning components of the apparatus ofFIG. 7 . -
FIG. 9 is a perspective view of a film quantity sensing apparatus. -
FIG. 10 is a block diagram of software modules of the software of which operates the apparatus. -
FIG. 11 is a perspective view of products along the vacuum conveyor. -
FIG. 11A is an end view illustrating a product wrapped in film material having a static seal. -
FIG. 11B is an end view illustrating a product wrapped in film material having a fin seal. -
FIG. 12 is a perspective view of apparatus with further panels removed. -
FIG. 13 is a perspective view of products interspersed with missing products along the vacuum conveyor. -
FIG. 14 is a simplified illustration of sealing and cutting operations of the apparatus with missing products interspersed. - Corresponding reference characters identify corresponding elements throughout the several views of the drawings.
- Referring to the drawings, the new shrink-wrap machine is generally indicated at 30 in
FIG. 1 . Referring toFIGS. 1-3 , shrink-wrap machine 30 comprises asupport frame 32 which supports aloading conveyor 34. As further shown, a wrappingstation 40 is disposedadjacent support frame 32. Additionally, afilm dispensing station 36 is disposedadjacent wrapping station 40. Asupport frame 38 secures avacuum conveyor 42 which is disposed adjacentfilm dispensing station 36.Support frame 38 securesexit conveyor 50 which is disposed a predetermined distance fromvacuum conveyor 42 with a film sealing and cuttingapparatus 44 interposed therebetween. Aguard frame 46 which encloses film sealing and cuttingapparatus 44, pivotally secures touchsensitive monitor 48. - As shown in
FIGS. 1, 3 and 3A, loadingconveyor 34 comprises asupport frame 32 for securing a slottedbelt 54 which proceeds in a longitudinal direction along loadingconveyor 34 beneathloading surface 35. Alongitudinal slot 37 is formed inloading surface 35, exposingbelt 54. Further, opposingguides 52 which run longitudinally along loadingsurface 35, may be selectively separated to correspond to the width ofproducts 58 proceeding longitudinally along loadingconveyor 34. To maintain a predetermined spacing betweenadjacent products 58, multiple equidistantly spaced product propelling means 56, preferably lugs, are inserted in slottedbelt 54. Slottedbelt 54 is driven by a motorized means 60, preferably a permanent magnet D.C. motor. A sensor 62 (not shown but represented by dashed line inFIG. 1 ) is disposed alongbelt 54 for sensing the position oflugs 56 aslugs 56 travel pastsensor 62. As can be appreciated by one skilled in the art,sensor 62 generates electrical signals in accordance with the Hall Effect. Using these generated electric signals permits shrink-wrap machine 30 to synchronize belt speeds and effect precise control ofproduct 58 position during operation. - Referring to
FIGS. 1 and 7 ,film dispensing station 36 is explained.Film dispensing station 36 is comprised of a pair ofvertical support members 64 which are securely connected to supportframe 38 bybrackets 66. Further, a proximally positionedvertical support member 64 is securely connected to anopen support end 68 having a pair of pivotingmembers 67 which are prevented from pivoting bypins 69. A distally positionedvertical support member 64 is securely connected to aclosed support end 70. Aspindle member 72 is disposed betweenopen support end 68 andclosed support end 70 for carrying a roll offilm material 92 thereon. Access for removal of a roll of film material is effected by actuatingpin 69 wherebymember 67 pivots to position 71. As is shown inFIG. 7 ,film dispensing station 36 may accommodate two separate rolls offilm material 92. - Referring to
FIGS. 7 and 8 ,spindle member 72 is further disclosed.Spindle member 72 comprises acentral shaft 94 which further includes adistal end 95 and aproximal end 96.Distal end 95 is nonrotatably attached toclosed support end 70. Anouter shaft 97 which further includes an inside surface 99 and anoutside surface 103 slides overcentral shaft 94 and is maintained in concentric rotational proximity alonglongitudinal axis 101 bymultiple bearings 98. A pair of lockingcollars 100 are slidably fitted upon opposing ends ofouter shaft 97 for securing a roll offilm material 92 therebetween. As is further shown,central shaft 94 includes a threadedportion 102 along itsproximal end 96.Adjustment collar 104 includes aproximal segment 107 having a knurledgripping surface 105 and adistal segment 109 having anoutside surface 111.Adjustment collar 104 further includes aknurled gripping surface 105 for ready operator adjustment. Additionally, a ring 108 having aninside surface 110 and anoutside surface 113 is fitted uponoutside surface 111 establishing a press fit therebetween. - Although shown in
FIG. 8 in an exploded view, outsidesurface 113 of ring 108 ofadjustment collar 104 is assembled into inside surface 99 ofouter shaft 97. Therefore,adjustment collar 104, ring 108 andouter shaft 97 are of integral construction. Thus, one of ordinary skill in the art can appreciate that asadjustment collar 104 is rotated aboutlongitudinal axis 101 after being placed in threaded engagement withcentral shaft 94, asadjustment collar 104 proceeds in either direction alonglongitudinal axis 101,outer shaft 97 likewise proceeds alonglongitudinal axis 101 due to the integral construction betweenadjustment collar 104 andouter shaft 97. Moreover, lockingnut 112 has a knurled grippingsurface 116 and an internally threadedaperture 114 that may be placed in threaded engagement with threadedportion 102. By graspingknurled gripping surface 116 androtating locking nut 112 alonglongitudinal axis 101 in a direction towardadjustment collar 104 until there is secure contact therebetween, lockingnut 112 will preventadjustment collar 104 from rotating with respect tocentral shaft 94. It is appreciated that this arrangement permits an operator to move afilm roll 92 in either direction alonglongitudinal axis 101 by rotatingadjustment collar 104 which is in threaded engagement withcentral shaft 94 in a desired direction alonglongitudinal axis 101 while the shrink-wrap machine 30 of the present invention is in operation. - Referring to
FIG. 7 , retardingdevice 74 is shown. Retardingdevice 74 includes anelongated member 76 having aproximal end 78 and recessed region 80 immediately adjacentproximal end 78. Further,distal end 82 is securely connected inclosed support end 70. Retardingdevice 74 is configured to receive aflexible retarding member 84. Flexible retardingmember 84 includes a first loop 86 which is pivotally engaged with recessed region 80 ofelongated member 76 and asecond loop 88 that secures aweight 90 for maintaining retardingmember 84 in position. As shown, flexible retardingmember 84 extends over and around the periphery of a roll offilm material 92, providing non-marring frictional resistance to rotation of a roll offilm material 92 aboutlongitudinal axis film material 92 aboutproducts 58. The frictional resistance that is generated betweeninner surface 85 and the periphery of a roll offilm material 92 is not specifically shown, asfilm material 92 is depicted in phantom lines for purposes of clarity. It is appreciated that this frictional force will tend to minimize the amount of unrestricted dispensing offilm material 92 when wrapping operation is halted. - Referring to
FIG. 9 ,indexing device 118 is further illustrated.Index device 118 includes anelongated portion 120 having aproximal end 122 and adistal end 124. As is shown,elongated portion 120 protrudes throughclosed support end 70 so thatelongated portion 120 may rotate about itslongitudinal axis 126. Further, afirst sensing member 128 extends radially fromproximal end 122, andsecond sensing member 130 extends radially fromdistal end 124. First sensingmember 128 andsecond sensing member 130 are situated in a predetermined angular relationship with each other and with respect tolongitudinal axis 126. As is further shown, a firstcurved slot 132 and a secondcurved slot 134 is formed inclosed support end 70. Additionally, afirst sensing device 136 and asecond sensing device 138 are disposed in firstcurved slot 132 and secondcurved slot 134, respectively for sensing a predetermined extent of depletion and total depletion, respectively, of a roll offilm material 92. It is further appreciated that a second set or pair of curved slots and sensing devices are provided asfilm dispensing station 36 is configured to secure two rolls offilm material 92.Sensing devices second sensing member 130 passes in sufficiently proximately therewith. Additionally, an operator warning device (not shown) may be provided for warning an operator of a predetermined extent of depletion or total depletion, respectively, of a roll offilm material 92. - Referring to
FIG. 9 ,first sensing member 128 rests atopouter surface 87 of flexible retardingmember 84 for monitoring the amount of shrink-wrap material 92 remaining on a roll.Second sensing member 130 is pivotally adjacent first andsecond sensing devices wrap material 92 is expended,first sensing member 128 maintains an offset tangential contact along the radius of the roll. This offset is due to the thickness of theflexible retarding member 84 asfirst sensing member 128 rotates aboutlongitudinal axis 126 of theelongated portion 120. Likewise,second sensing member 130 rotates aboutlongitudinal axis 128. As the film roll of shrink-wrap material 92 is expended to a predetermined level,second sensing member 130 achieves such proximity withfirst sensing device 128 as to activatefirst sensing device 136 and thereby alert an operator of a predetermined level of depletion offilm material 92 from a film roll. Upon the roll being totally expended offilm material 92,second sensing member 130 achieves such proximity withsecond sensing device 138 as to activatesecond sensing device 138 thereby alerting the operator thatfilm material 92 of a film roll has been totally expended. - Referring to
FIGS. 1 and 3 , wrappingstation 40 is disposedadjacent loading conveyor 34 for receiving products propelled bylug 56. Wrappingstation 40 is well known in the art, usingfilm material 92 for wrappingproduct 58 by directingfilm material 92 fromfilm dispensing station 36 to closely wrapproducts 58 peripherally along their longitudinal axes within acontinuous tube 93 offilm material 92 so thattube 93 is formed therearound product 58 (FIG. 11 ). Referring toFIGS. 11A , an overlappingregion 81 is formed between opposed ends 79 offilm material 92. A sealing device 41 (FIG. 1 ) disposedadjacent wrapping station 40 establishes acontinuous seam 77 along overlappingregion 81. Referring toFIG. 1 , wrappingstation 40 establishes a static seal. Although different types of wrapping stations are used to form different kinds of seals (FIGS. 11A, 11B ), which are also known in the art, shrink-wrap machine 30 of the present invention provides formodular wrapping stations 40 which may be selectively installed according to a customer's preference. - Referring to
FIGS. 1 and 6 A,vacuum conveyor 42 is disposed adjacentfilm dispensing station 36 and carriesfilm tube 93 which is very closely wrapped aroundproduct 58. Further, by generating a partial pressure alongvacuum conveyor 42,products 58 are sequentially conveyed without their being shifted from the position at whichproduct 58 first makes contact withvacuum conveyor 42. Moreover, movement alongvacuum conveyor 42 is maintained in synchronization withloading conveyor 34 because the motorized means, preferably a stepper motor, drivingvacuum conveyor 42 receives electrical signals generated bysensor 62, which is most preferably a Hall Effect sensor, and which produces a voltage each time alug 56 passes sensor 62 (not shown). This arrangement permitsuniform spacing 150 betweenadjacent products 58 travelling along the longitudinal axis ofvacuum conveyor 42. - Referring to
FIGS. 2, 4 , 5, and 6A-6D, film sealing and cuttingapparatus 44 is disposed at a predetermined fixed distance fromvacuum conveyor 42. Additionally,apparatus 44 is configured to move into and out of engagement between adjacent film wrappedproducts 58. In making these movements,apparatus 44 places atransverse cut 91 or end seal between adjacent sequentially presentedproducts 58 before passing newly separatedproducts 58, or packages 59 (FIGS. 6A, 6D ), ontoexit conveyor 43. - Referring to
FIGS. 4 and 5 ,upper gear 142 is rotatably connected to framestructure 140 aboutcenter axis 144. As is shown, fixedcentral gear 146 is non-rotatably secured alongcenter axis 144. Firsteccentric gear 148 which is carried byuppergear 142 meshes withcentral gear 146 that further meshes with secondeccentric gear 150 which is also carried byupper gear 142. As is further shown, secondeccentric gear 150 rotates abouteccentric axis 152. - Therefore, as
upper gear 142 rotates aboutcenter axis 144, firsteccentric gear 148 is urged into rotation by meshing engagement withcentral gear 146. Additionally, secondeccentric gear 150 which rotates abouteccentric axis 152 is placed in opposing rotation with respect toupper gear 142. Thus, secondeccentric gear 150, although eccentrically rotating aboutcenter axis 144, rotates abouteccentric axis 152 so thatlower gear 162 is maintained in alignment withvertical axis 200. As is shown in FIGS. 5A and 6A-6D, rotation of secondeccentric gear 150 abouteccentric axis 152 is best explained by use ofreference point 153.Reference point 153 inFIG. 5A appears on the upper periphery of secondeccentric gear 150 in-line withvertical axis 200. Referring toFIG. 5B ,reference point 153 continues to appear at the top vertical position of secondeccentric gear 150 in-line withvertical axis 200. Therefore, as shown onFIGS. 5A and 5B and 6A-6B, whilelower gear 162 completes a rotation cycle aboutcenter axis 170, secondeccentric gear 150 rotates abouteccentric axis 172 so thatupper head 156 remains parallel tovertical axis 200. - Referring to
FIGS. 4 and 5 ,upper head 156 includes a body 154 having a pair of in-line apertures 155 on opposing ends of body 154.Apertures 155 accept opposingshafts 157 which extend from secondeccentric gears 150 for rotational orientation with respect toeccentric axis 152.Upper head 156 further includes acutter portion 158 disposed between a pair of film clamps 160.Cutter portion 158 and film clamps 160 are slidably movable along pins 161. Further, multiple hat-shapedstructures 163 are biased againstmultiple springs 159 to force bothcutter portion 158 and film clamps 160 in an extended position. - Referring to
FIG. 5 ,lower gear 162 includes a fixedcentral gear 146 which is non-rotatably mounted toframe structure 140, althoughlower gear 162 may rotate aboutcenter axis 170. As is shown, firsteccentric gear 148 meshes withcentral gear 146 and secondeccentric gear 150 likewise meshes with firsteccentric gear 148. Secondeccentric gear 150 rotates abouteccentric axis 172. Therefore, aslower gear 162 rotates aboutcenter axis 170, firsteccentric gear 148 is urged into rotation by meshing engagement withcentral gear 146. Additionally, secondeccentric gear 150 which rotates abouteccentric axis 172 is placed in opposing rotation with respect tolower gear 162. Thus, secondeccentric gear 150, although eccentrically rotating aboutcenter axis 170, rotates abouteccentric axis 172 so thatlower gear 162 is maintained in alignment withvertical axis 200. As is shown in FIGS. 5A and 6A-6D, rotation of secondeccentric gear 150 abouteccentric axis 152 is best explained by use ofreference point 153.Reference point 153 inFIG. 5A appears on the upper periphery of secondeccentric gear 150 in-line withvertical axis 200. Referring toFIG. 5B ,reference point 153 continues to appear at the top vertical position of secondeccentric gear 150 in-line withvertical axis 200. Therefore, as shown onFIGS. 5A and 5B and 6A-6B, whileupper gear 142 completes a rotation cycle aboutcenter axis 144, secondeccentric gear 150 rotates abouteccentric axis 152 so thatupper head 156 remains parallel tovertical axis 200. - As is shown in
FIGS. 4 and 5 ,lower head 164 includes abody 174 having a pair of in-line apertures 176 on opposing ends ofbody 174.Apertures 176 accept opposingshafts 151 which extend from secondeccentric gears 150 for rotational orientation with respect toeccentric axis 172.Body 174 further includes multiple apertures 178 for accepting in sliding contact therein pins 180 which protrude fromplaten portion 182.Springs 184 are fitted uponpins 180 prior to insertion intobody 174 andbias body 174 in a direction away fromplaten head portion 182, that is, in a direction along the longitudinal axes ofpins 180. - Referring to
FIGS. 4 and 5 , the interrelationship betweenupper gear 142 andlower gear 162 is now explained. A pair ofserpentine belts 186 mesh about the peripheries ofupper gear 142 andlower gear 162. Eachserpentine belt 186 meshes anouter pulley 188 secured in non-rotating orientation with respect to ashaft 192, with aninner pulley 190 being disposed betweenouter pulleys 188 alongshaft 192.Shaft 192 is journaled to framestructure 140. As is further shown, abelt 194 engagesinner pulley 190 andpulley 196 of motorized means 198, preferably a servo motor. One skilled in the art can appreciate thatupper gear 142 andlower gear 162 are being driven in opposing rotational directions about their respective center axes 144, 170. As further appreciated thatupper head 156 is carried having a fixed angle of orientation, preferably withvertical axis 200, and thatlower head 164 is likewise carried having a fixed angle of orientation, preferably in alignment withvertical axis 200. Referring toFIGS. 6A-6D , it is appreciated thatupper head 156 andlower head 164 are maintained synchronously and mutually toward and away from each other about a predetermined path. Thus,cutter portion 158 ofupper head 156 andplaten head portion 182 oflower head 164 are engaged once for every full rotation ofupper gear 142 andlower gear 162. Additionally, due to the rotation ofupper head 156 with respect toeccentric axis 152 andlower head 164 with respect toeccentric axis 172, it is appreciated thatupper head 156 and thelower head 164 rotate in and out of engagement while maintaining a fixed angle of orientation, preferably in-line with avertical axis 200. Further, it is appreciated thatcutter portion 158 and theplaten head portion 182 each maintain a predetermined path, preferably circular, due to the epicyclical arrangement withgears - Referring to
FIG. 12 , the vertical adjustment of film sealing and cuttingapparatus 44 now disclosed. It is appreciated, that for symmetry,apparatus 44 most efficiently performs its task by engaging film material along a product's mid-point axis 202 (FIG. 6A ). Thus, a means to vertically adjust theentire apparatus 44 is required. This is effected, by use of a motorized means 218, such as a permanent D.C. motor. Motorized means 218 is secured to supportframe 38 for driving achain belt 220 which engages agear 222.Gear 222 is secured to aproximal end 226 of ashaft 224 with a mounting means 228 securing to adistal end 229 ofshaft 224. Further,bevel gears 230 are disposed alongshaft 224 and at proximal ends 232 of threadedshafts 234.Shafts 234 are threadedly engaged withblocks 236 ofapparatus 44. Thus, motorized means 218drives gear 222, which imparts rotation toshaft 222 that further rotatesbevel gears 230 disposed alongshaft 224. Further,bevel gears 230 at proximal ends 232 of threadedshafts 234, being meshed withbevel gears 230 alongshaft 224, impart rotation about threadedshafts 234. By rotating threadedshafts 234 with respect toblocks 236,apparatus 44 is raised or lowered until the desired height is reached. - Referring to
FIGS. 1 and 6 A,exit conveyor 50 is disposed in close proximity withapparatus 44 andvacuum conveyor 42.Exit conveyor 50 receives sequentially deliveredproducts 58 fromvacuum conveyor 42 andapparatus 44 after atransverse seal 91 has been placed between eachadjacent product 58. A motorized means 236 (FIG. 12 ), preferably a permanent magnet D.C. motor, is utilized to carryproducts 58 sequentially therefrom in a predetermined relationship with respect to loadingconveyor 34. As will be explained in greater detail below, the operator may find it desirable to driveexit conveyor 50 at a lower speed thanvacuum conveyor 42 is driven. - Referring to
FIGS. 1, 3 and 7, a novel, user-friendly feature of shrink-wrap machine 30 is disclosed. A touchsensitive monitor 48 includes anarm 49 which is pivotally engaged withguard frame 46. Further,film dispensing station 36 includes an open support end 68 from which anoperator 47 may either load or unload a roll offilm material 92. Anoperator 47 may grasp monitor 48 and pullmonitor 48 towards the operator so thatarm 49 pivots aboutguard frame 46, thus movingmonitor 48 on the same side ofmachine 30 asopen support 68 offilm dispensing station 36. Additionally,operator 47 may rotate monitor 48 about itsbase 51 if desired. By having both monitor 48 andopen support 68 on the same side ofmachine 30, maintenance and normal operations are greatly simplified. Moreover, becausemonitor 48 can be pivoted to either side, and due to interchangeability betweensupport 68 andsupport 70 offilm dispensing station 36,machine 30 is ambidextrous. That is,operator 47 may choose a desired side of operations ofmachine 30. - Referring to
FIG. 10 , flow diagram 250 is now explained. Flow diagram 250 includes the following modules which are contained in a box and includes set-upprogram 252, which after a reference button is pushed (Step 253), proceeds intohoming program 254 that thereafter proceeds into eithermain program 256 or toPLC program 258. Afault program 260 continuously runs in the background but is not specifically part of the flow diagram. These microprocessor-driven programs define a control system for the machine. - Set-up
program 252 includes initializing variables for operation of the machine and include provision for the operator to: -
- specify the height, width and length of a package
- indicate type of seal desired
- set the speed of the loading conveyor
- set the speed of exit conveyor
- set the temperature of cutting head.
- Additionally, set-up
program 252 sets the scaling for the servo axis which includes a predetermined number of counts per degree rotation of sealing and cuttingapparatus 44, andvacuum conveyor 42 which additionally has a predetermined number of counts per unit displacement along the longitudinal direction ofvacuum conveyor 42. This scaling permits shrink-wrap machine 30 to extremely accurately calculate the position ofproducts 58 as they proceed downvacuum conveyor 42 and reachapparatus 44. Additionally, set-upprogram 252 sets error checking bits, the violation of which may terminate operation of shrink-wrap machine 30. -
Homing program 254 must be initially invoked by depressingreference button 253. Oncereference button 253 is depressed, homingprogram 254 finds the film clamping zone 262 (FIGS. 6B, 6C ).Film clamping zone 262 refers to the angular range in whichupper head 156 andlower head 164 are in contact withfilm material 92 between adjacent products. Additionally, homingprogram 254 calculates the top dead center position (not shown), whereinupper head 156 is located at its uppermost position in its movement cycle andlower head 164 is positioned at its lowest vertical position with respect to its cycle of movement. Therefore, the top bid center position corresponds to the tallest product that the shrink-wrap machine can accommodate. Moreover, homingprogram 254 also references the ceiling height to which motorized means 218 must moveapparatus 44 so thatupper head 156 andlower head 164 are engaged at a height that corresponds to one-half of the height of an incoming product down thevacuum conveyor 42.Main program 256 controls the normal operation of all motor positions or axes. In addition,main program 256 calculates the ratios between web matching and cam following. Web matching refers to matching the speed ofproduct 58 alongvacuum conveyor 42 with the horizontal speed ofapparatus 44 whileupper head 156 andlower head 164 are in the film clamping zone. Cam following refers to the 360 degree rotational speed motion ofupper head 156 andlower head 164. -
PLC program 258 monitors all machine input and output stations while continuously scanning.Reference button 253 is pushed only when initially turning on the machine and is not again required to be pressed until after a machine is shut off, it is only during the initial turn-on period. -
Full program 260 monitors all machine fault bits continuously as it is a program that runs in the background.Fault program 262 monitors commands based on error bit detection, taking predetermined steps to address any particular error. Some error bits can be operator configured such as electing or not electing to activate an alarm when a film roll is expended. - Set-up
program 252 permits an operator great flexibility and ease of operation by permitting the operator to input dimensions for different packages to be processed without the operator having to otherwise physically make any other alterations to the shrink-wrap machine. - Referring to
FIGS. 1, 2 , 3, 3A, 6A-6D, 11, and 11A-11B, the operation ofmachine 30 shall be discussed. Afteroperator 47 has turned on themachine 30 and has made selections on touchsensitive monitor 48,machine 30 indicates onmonitor 48 the proper spacing forlugs 56 alongloading conveyor 34. Additionally, thecorrect wrapping station 40 must be installed intomachine 30. Further, at least one roll offilm material 92 must be loaded ontofilm dispensing station 36 and threaded through wrappingstation 40 before the wrapping process forproducts 58 may commence.Products 58 are placed on loadingconveyor 34 and properly spaced as shown inFIG. 3A and sequentially propelled into wrappingstation 40 bylugs 56.Products 58 then begin to pass in sequential procession through wrappingstation 40, wherein each product is closely wrapped peripherally about its longitudinal axis within a continuous tube offilm material 93 formed therearound. Opposing ends of shrink-wrap material 92wrap products 58, forming regions of overlapping shrink-wrap material 81 along the products' longitudinal axes. A sealing device in association with the modular wrapping station 40 (not shown) establishes acontinuous seam 77 along the region of overlapping shrink-wrap material 81. It can be appreciated by one skilled in the art that wrappingstation 40 may be of multiple configurations. Therefore, the region of overlappingmaterial 81 may be differently configured as would be the sealing arrangement required to establish theseam 77 between overlappingmaterial 81. - Referring to
FIG. 6A ,products 58 proceeding alongvacuum conveyor 42 are snugly wrapped in atube 93, and move with the film wrap material at a firstpredetermined spacing 204 therebetween.Products 58 further proceed alongvacuum conveyor 42 toward film sealing and cuttingapparatus 44 for receiving atransverse seal 91 between each adjacently positionedproduct 58. - Referring to
FIGS. 6A-6D , the process for introducingtransverse cuts 91 betweenadjacent products 58 is now discussed. For clarity, an additional distinction between products is shown by reference characters character A, B, C or D within the product box. Thus, referring toFIG. 6A , package A has already passed film sealing and cuttingapparatus 44, is onexit conveyor 43 and ready for delivery into heat chamber (not shown). The term “package” is applied to wrapped products that have received transverse seals of film material in front of its leading end and after its trailing end. Product B has received atransverse seal 91 in front of itsleading end 208 withcutter portion 158 andplaten head portion 182 rotating in position to place atransverse seal 91 between trailingend 210 of product B andleading end 212 of product C. Further, as shown onFIG. 6A , the spacing between adjacent products such as between product C and product D which initially is firstpredetermined spacing 204, may be revised or reduced such as between product B and C to a secondpredetermined spacing 206. This reduced spacing may be desirable for ataller product 58. Therefore, assuming theproduct 58 to be tall, to effect the shorter secondpredetermined spacing 206,exit conveyor 43 must operate at a slightly slower speed than that ofvacuum conveyor 42. Thus, as leadingend 208 of product B comes into contact withexit conveyor 43, the speed of product B becomes slightly less with respect to product C which is still onvacuum conveyor 42, thereby producing secondpredetermined spacing 206 between product B and product C. This reduced spacing produces a condition of reduced tension offilm tube 93 which permitcutter portion 158 andplaten head portion 182 to effect an improvedtransverse seal 91 between product B and product C. - Referring to
FIG. 6B , cuttingportion 158 andplaten head portion 182 first come into contact withfilm tube 93. This range of contact betweencutter portion 158 andplaten head portion 182 is referred to as thefilm clamping zone 262 which extends 20 degrees to either side of thevertical axis 200. It may be appreciated that maintainingupper head 156 andlower head 164 and fixed relationship therebetween, preferably alongvertical axis 200, permits an improved seal due to equal tension offilm tube 93 between product B and product C. As is shown onFIG. 6C , cuttinghead 158 andplaten portion 182 remain in contact with each other, and have effected atransverse seal 91 between product B and product C. Further,FIG. 6D showscutter portion 158 andplaten head portion 182 movement out of contact from between product B and product C,transverse seal 91 having been formed therebetween. As is appreciated, this process for establishingtransverse seal 91 is sequentially repeated for product C, B and so on. - Moreover, an additional operational aspect of the
machine 30 is discussed. As earlier noted, sensor 62 (not shown) senses a product propelling means 56, preferably lugs, not theproduct 58 itself. Thus,sensor 62 generates signals corresponding to ananticipated product 58 position, irrespective of the existence of aproduct 58 in that position. Referring toFIGS. 13 and 14 , this “missing product” condition is illustrated. For clarity, an additional distinction between products is shown by reference characters character A, B, C or D within the product box or if there is no product, i.e., a missing product, the character is circled. As is illustrated inFIG. 13 wrapped in continuousfilm material tube 93, products B and D appear interposed with missing products A and C. - Referring to
FIG. 14 , it is shown that missing product A and product B have been separated bytransverse seal 91 and missing product C has received a firsttransverse seal 91. Therefore, without operator intervention, and so long assufficient film material 92 remains onfilm dispensing station 36,machine 30 operates normally. That is, film sealing and cuttingapparatus 44 will continue to formtransverse seals 91 infilm tube 93 between anticipated positions ofadjacent products 58. - In addition, a method for controlling a shrink-wrap machine comprises:
-
- a) initializing variables;
- b) setting scaling for the sealing head and the vacuum conveyor axes;
- c) setting error checking bits;
- d) selectively locating a film clamping zone and calculating a top dead center position for the sealing head;
- e) controlling normal operations of all motor axes;
- f) calculating ratios for web matching and cam following;
- g) monitoring all machine input/output ports by continuously scanning same;
- h) monitoring continuously all machine fault bits;
- i) executing commands based on error bits;
- j) repeating steps a)-c) and steps e)-i) upon user re-initialization of package size or other modes as long as machine is not turned off.
- In view of the foregoing description of the present invention and various embodiments and methods it will be seen that the several objects of the invention are achieved and other advantages are attained.
- The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.
- As various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting.
Claims (21)
1. (canceled)
2. (canceled)
3. (canceled)
4. (canceled)
5. (canceled)
6. (canceled)
7. (canceled)
8. (canceled)
9. (canceled)
10. (canceled)
11. (canceled)
12. (canceled)
13. (canceled)
14. (canceled)
15. (canceled)
16. (canceled)
17. (canceled)
18. (canceled)
19. (canceled)
20. (canceled)
21. A method for controlling a shrink-wrap machine having a sealing head and vacuum conveyor axes, drive motors having drive axes, and machine input/output ports, comprising:
a) initializing variables;
b) setting scaling for the sealing head and the vacuum conveyor axes;
c) setting error checking bits;
d) selectively locating a film clamping zone and calculating a top dead center position for the sealing head;
e) controlling normal operations of all motor axes;
f) calculating ratios for web matching and cam following;
g) monitoring all machine input/output ports by continuously scanning same;
h) monitoring continuously all machine fault bits;
i) executing commands based on error bits;
j) repeating steps a)-c) and steps e)-i) upon user re-initialization of package size or other modes as long as the machine is not turned off.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/028,977 US20050150188A1 (en) | 2000-10-30 | 2005-01-04 | Modular shrink-wrap machine |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US24436000P | 2000-10-30 | 2000-10-30 | |
US10/036,029 US6854242B2 (en) | 2000-10-30 | 2001-10-29 | Modular shrink-wrap machine |
US11/028,977 US20050150188A1 (en) | 2000-10-30 | 2005-01-04 | Modular shrink-wrap machine |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/036,029 Division US6854242B2 (en) | 2000-10-30 | 2001-10-29 | Modular shrink-wrap machine |
Publications (1)
Publication Number | Publication Date |
---|---|
US20050150188A1 true US20050150188A1 (en) | 2005-07-14 |
Family
ID=22922401
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
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US10/036,029 Expired - Lifetime US6854242B2 (en) | 2000-10-30 | 2001-10-29 | Modular shrink-wrap machine |
US11/028,977 Abandoned US20050150188A1 (en) | 2000-10-30 | 2005-01-04 | Modular shrink-wrap machine |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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US10/036,029 Expired - Lifetime US6854242B2 (en) | 2000-10-30 | 2001-10-29 | Modular shrink-wrap machine |
Country Status (4)
Country | Link |
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US (2) | US6854242B2 (en) |
AU (1) | AU2002234142A1 (en) |
CA (1) | CA2426826C (en) |
WO (1) | WO2002036431A2 (en) |
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Also Published As
Publication number | Publication date |
---|---|
WO2002036431A3 (en) | 2002-09-06 |
US20020055803A1 (en) | 2002-05-09 |
WO2002036431A2 (en) | 2002-05-10 |
AU2002234142A1 (en) | 2002-05-15 |
CA2426826C (en) | 2009-01-20 |
US6854242B2 (en) | 2005-02-15 |
CA2426826A1 (en) | 2002-05-10 |
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