Methods and apparatus for adjustable wrapping

Abstract

Methods and apparatus for wrapping products having different product profiles includes a conveyor ( 14, 18, 22 ) driven by a conveyor drive ( 34 ) transporting a product ( 26 ). A wrapping mechanism ( 46 ) includes a drive mechanism ( 74 ) moving a wrap support ( 86 ) about a wrapping mechanism axis ( 58 ) using a rotatable driver ( 62 ) and a carrier ( 78 ) extending between the driver ( 62 ) and the wrap support ( 86 ). In one preferred form, a slideable attachment between the driver ( 62 ) and the carrier ( 78 ) allows extension and retraction of the wrap support ( 86 ) according to the product profile of the product ( 26 ). In one preferred form, a guide ( 82 ) moves in an adjustable cam track ( 98 ) made up of multiple segments ( 102, 106 ) to define a path ( 94 ) of the wrap support ( 86 ). The cam track ( 98 ) corresponds to the product profile of the product ( 26 ) on the platform ( 30 ). One of the cam segments ( 102, 106 ) is separately removable to allow for adjustment of the cam track ( 98 ). The wrap support ( 86 ) engages a film ( 134 ) and wraps the film ( 134 ) around the product ( 26 ). In a preferred form, a sensor ( 118 ) detects the product ( 26 ) as it proceeds toward the conveyor ( 18 ). A tracking encoder ( 122 ) receives data from the sensor ( 118 ) and the conveyor drive ( 34 ) to track the position of the product ( 26 ). A controller ( 126 ) receives the information from the tracking encoder ( 122 ) and controls the wrapping mechanism ( 46 ) according to the wrapping profile to accommodate variable spacing of products ( 26 ). A graphical user interface ( 130 ) may be used to modify or create wrapping profiles.

1 . An apparatus for wrapping a product having a product profile with a sheet of material, the apparatus comprising, in combination: a driver mounted for rotation about an axis; a wrap support for engaging and directing the sheet of material around the product; a carrier extending between the driver and the wrap support for moving the wrap support in a path around the axis; a cam track mounted relative to the axis; and a cam follower mounted relative to and moveable with the wrap support, with movement of the cam follower by rotation of the driver about the axis and relative to the cam track causing movement of the wrap support to differing radial spacings relative to the axis in the path and accommodating the product profile.  
     
     
         2 . The apparatus of  claim 1  with the cam track comprising a plurality of segments of which at least one is interchanged allowing the cam track to substantially match different product profiles.  
     
     
         3 . The apparatus of  claim 1  with the carrier comprising a linear element attached to the wrap support and radially slideable relative to the driver allowing for extension and retraction of the wrap support relative to the driver.  
     
     
         4 . The apparatus of  claim 1  further comprising, in combination: a controller computing a speed for the wrap support to fit the product profile.  
     
     
         5 . The apparatus of  claim 4  with the controller containing data for a plurality of wrapping profiles.  
     
     
         6 . The apparatus of  claim 4  further comprising, in combination: a servomotor for rotating the driver around the axis and for providing data to the controller on the position of the wrap support.  
     
     
         7 . The apparatus of  claim 6  further comprising, in combination: a sensor that detects a leading edge of the product and for providing data to the controller on the position of the product.  
     
     
         8 . The apparatus of  claim 7  further comprising, in combination: a tracking encoder that receives data from the sensor and that tracks the location of the product.  
     
     
         9 . The apparatus of  claim 4  further comprising, in combination: a sensor that detects a leading edge of the product and for providing data to the controller on the position of the product.  
     
     
         10 . The apparatus of  claim 4  with the controller computing the speed for the wrap support according to a single segment cubic spline.  
     
     
         11 . An apparatus for wrapping a product having a product profile with a sheet of material, the apparatus comprising, in combination: a wrap support for engaging and directing the sheet of material around the product, with the wrap support being moveable along a continuous path; a cam track; and a cam follower, with one of the cam follower and the cam track being mounted and moveable with the wrap support, with movement of the wrap support along the continuous path causing relative movement between the cam follower and the cam track to move the wrap support according to the cam track, with the cam track comprising a plurality of cam segments corresponding to a portion of the continuous path, with at least one of the plurality of cam segments being interchangeable allowing the cam track to create different shapes for the continuous path.  
     
     
         12 . The apparatus of  claim 11  with the plurality of cam segments including an upper segment and a lower segment, with the product being supported upon a platform, with the upper segment including a portion of the cam track corresponding to the path vertically above the platform and the lower segment including a portion of the cam track corresponding to the path vertically below the platform, with the at least one of the plurality of cam segments being the upper segment.  
     
     
         13 . The apparatus of  claim 12  with the upper segment and the lower segment completely defining a set route from the continuous path.  
     
     
         14 . The apparatus of  claim 11  with another cam track mounted substantially parallel to the cam track and another cam follower associated with the other cam track.  
     
     
         15 . The apparatus of  claim 11  further comprising, in combination: a controller having data corresponding to a plurality of wrapping profiles, with each wrapping profile associated with a specific product, with the data of the controller including the different shapes for the continuous path.  
     
     
         16 . A method for wrapping a product with a sheet of material, comprising: 
 moving a product for wrapping to a predetermined product position, with the product having a product profile;    rotating a driver about an axis;    engaging the sheet of material with a wrap support;    extending a carrier between the driver and the wrap support for moving the wrap support in a path around the axis;    moving the wrap support to differing radial spacings from the axis during rotation of the driver about the axis to direct the sheet of material around the product to accommodate the product profile of the product, with moving the wrap support comprising moving the wrap support to a desired location and recording the predetermined product position and the desired location to define a cam point; and    defining a series of cam points to create a custom wrapping profile.    
     
     
         17 . The method of  claim 16  further comprising saving the custom wrapping profile for each of a plurality of products.  
     
     
         18 . The method of  claim 16  with moving the wrap support comprising: 
 selecting a plurality of cam segments;  
 attaching the plurality of selected cam segments to create a cam track corresponding to the product profile; and  
 moving a cam follower relative to the cam track, with one of the cam track and the cam follower being moveable with the wrap support.  
 
     
     
         19 . A method for wrapping products with a sheet of material, comprising: 
 attaching a first plurality of interchangeable segments to form a first cam track according to a first wrapping path;    transporting a first product having a first product profile for wrapping;    extending and retracting a wrap support according to the first cam track to direct the sheet of material around the first product;    replacing at least some of the first plurality of interchangeable segments to create a different plurality of interchangeable segments to form a second cam track according to a second wrapping path, with the second wrapping path being different from the first wrapping path; and    transporting a second product having a second wrapping product for wrapping, with the second product profile being dissimilar to the first product profile.    
     
     
         20 . An apparatus for wrapping products comprising, in combination: a conveyor system for transporting product through a wrap location for wrapping; a wrapping mechanism having at least one wrap support moving through a wrap sequence and a nonwrap sequence; with the at least one wrap support disposed to direct a sheet of material around the product at the wrap location during a wrap sequence; and a controller receiving data on the movement of the product by the conveyor system and directing movement of the at least one wrap support to begin the wrap sequence according to a wrapping profile with respect to the product.  
     
     
         21 . The apparatus of  claim 20  with the conveyor system comprising a servomotor for providing data to the controller on the movement of the product.  
     
     
         22 . The apparatus of  claim 21  with the conveyor system comprising: a first conveyor; a wrap location conveyor; and a second conveyor, the conveyor system being arranged linearly, with each conveyor having a gap with the next conveyor sufficient to allow the wrap support to pass between the conveyors, with the wrap sequence commencing as the wrap support passes the gap between the first conveyor and the wrap location conveyor and ending as the wrap support passes the gap between the wrap location conveyor and the second conveyor, with the controller positioning the wrap support during the nonwrap sequence.  
     
     
         23 . The apparatus of  claim 20  where the wrapping profile includes a location and speed for beginning the wrap sequence.  
     
     
         24 . The apparatus of  claim 23  where the controller computes the movement of the wrap support through the nonwrap sequence using a single segment cubic spline.  
     
     
         25 . A method for controlling a wrap sequence and a nonwrap sequence of a wrap mechanism to allow for random spacings of products to be wrapped, comprising: 
 receiving data on position of the product for wrapping;    moving the wrap mechanism through the wrap sequence at a speed and position determined by the data of the position of the product.    
     
     
         26 . The method of  claim 25  with moving the wrap mechanism through the wrap sequence being determined by a profile of the product.