Apparatus and method for binding a load with tape

Abstract

An apparatus for binding a three-dimensional load with tape comprises a turntable for rotating the load, a tape dispenser and a logistical controller. The tape dispenser is moveable relative to the turntable and the load. The detector detects the top of the load, and is moveable with the tape dispenser. The logistical controller is arranged to control rotation of the load and movement of the tape dispenser. In particular, the controller is arranged to operate the apparatus to dispense the tape according to a predetermined default pattern until the detector determines the top of the load. Once the tope of load is detected, the controller is arranged to operate the apparatus according to a corrected pattern based upon the detected top of load. Further, the controller may comprise a computer program which calculates the required turntable speed for a substantially constant predetermined speed of the carriage such that the relative position of the turntable and the carriage is such that the load is bound according to the default pattern or the corrected pattern.

1 . An apparatus for binding a three-dimensional load with tape, the apparatus comprising: 
 a turntable for supporting and rotating the three-dimensional load;    a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load;    a logistical controller arranged to control rotation of the load and movement of the tape dispenser; and    a detector to detect the top of the load, the detector being moveable with the tape dispenser, wherein the controller is arranged to operate the apparatus to dispense the tape according to a predetermined default pattern until the detector determines the top of the load, whereafter, the controller is responsive to a signal from the detector corresponding to the detected top of load to operate the apparatus according to a corrected pattern based upon the detected top of load.    
   
   
       2 . The apparatus as defined in  claim 1  wherein the tape dispenser is provided on a moveable carriage driven up and down a mast, and the detector is mounted on the carriage.  
   
   
       3 . The apparatus as defined in  claim 2  wherein the detector is spaced above the tape dispenser to provide advance warning to the controller in an upward path of the tape dispenser that the tape is approaching the top of the load.  
   
   
       4 . The apparatus as defined in  claim 1  wherein the corrected pattern applied to the load is a helical pattern comprising a plurality of upward and downward helixes which are spaced from each other with at least some of the upward helixes crossing at least some of the downward helixes, the upward and downward helixes extending between upper and lower limits and wherein the default pattern comprises an upward helix and the controller operates the apparatus to dispense the tape in the upward helix of the default pattern according to a default pitch.  
   
   
       5 . The apparatus as defined in  claim 4  wherein the tape is applied at a default pitch until the detector detects the top of the load, whereafter the controller calculates a corrected pitch and operates the apparatus to apply the remaining upward and downward helixes at the corrected pitch.  
   
   
       6 . The apparatus as defined in  claim 5  wherein the corrected pitch is calculated so that the tape will be applied to a whole number of sides of the load as it traverses between the upper and lower limit and vice versa.  
   
   
       7 . The apparatus as defined in  claim 1  wherein the controller controls the apparatus to commence at an intermediate height of the load.  
   
   
       8 . The apparatus as defined in  claim 4  wherein the controller is arranged to receive a number of user inputs through the use of a keypad or other data entry means including values corresponding to the upper and lower limits of the pattern array, the pattern array being the vertical extent of the applied default and corrected helical patterns.  
   
   
       9 . The apparatus as defined in  claim 8  wherein the controller is arranged to calculate the array height from an input from the detector and the values corresponding to the upper and lower limits of the pattern array and wherein the controller determines the corrected pattern based on the array height.  
   
   
       10 . The apparatus as defined in  claim 4  wherein the controller determines an adjustment which is required in the default pattern so that the tape reaches the upper limit coinciding with the end of an inclined pass of tape across a side of the load.  
   
   
       11 . A method of binding a three-dimensional load with tape, the method comprising: 
 a) binding the load with tape dispensed from a movable tape dispenser according to a default pattern;    b) detecting the top of the load by a detector moveable with the tape dispenser during step a); and    c) binding the load with a corrected pattern based on the detected top of load.    
   
   
       12 . An apparatus for binding a three dimensional load with tape, the apparatus comprising: 
 a turntable to rotate the load;    a carriage to carry a tape dispenser for movement along an upward path and a downward path adjacent the load;    a controller to control the movement of the turntable and the carriage to bind the load according to a desired pattern, wherein the controller comprises a computer program which calculates the required turntable speed for a substantially constant predetermined speed of the carriage over a substantial portion of the upward path or a substantial portion of the downward path such that the relative position of the turntable and the carriage is such that the load is bound according to the desired pattern.    
   
   
       13 . The apparatus as defined in  claim 12  wherein the carriage speed is constant over an intermediate portion of both of the upward and the downward paths to allow for acceleration and deceleration at the extremes of the paths.  
   
   
       14 . The apparatus as defined in  claim 13  wherein the apparatus is operable to determine predefined parameters of the load during the binding operation and the carriage has two possible constant speeds being a fast speed and a slow speed and wherein the controller is arranged to operate the apparatus to apply tape at the slow speed to apply a default pattern which is pre-programmed into the controller and the controller is arranged to operate the apparatus to apply tape at the fast speed according to a pattern which is determined by the controller once the predefined parameters of the load are determined.  
   
   
       15 . The apparatus as defined in  claim 12  wherein the apparatus is adapted to bind a three dimensional load which is square or rectangular and the desired pattern for the tape is broken down into segments of quarter turns of the turntable by the controller to determine, for each quarter turn: the required position of the carriage to apply tape according to the desired pattern; when the carriage will arrive at the required position; and the speed of the turntable required to rotate the load through said quarter turn.  
   
   
       16 . An apparatus for binding a load with tape, the apparatus comprising: 
 a turntable for supporting and rotating the three-dimensional load;    a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load; and    a logistical controller arranged to control rotation of the load and movement of the tape dispenser; wherein the controller is arranged to operate the apparatus to dispense the tape according to a desired pattern comprising a plurality of helical paths, each path including at least one upward helix, a loop over the top of the load and a downward helix giving rise to a pattern whereby the upward and downward helixes are transversely spaced from each other and each upward helix crosses with at least one downward helix.    
   
   
       17 . The apparatus as defined in  claim 16  wherein the apparatus includes a data entry means for the operator to select the desired pattern from a variety of pattern options.  
   
   
       18 . The apparatus as defined in  claim 17  wherein the data entry means is also adapted to receive operator entry of one or more parameters of the looping.  
   
   
       19 . An apparatus for binding a three-dimensional load with tape, the apparatus comprising a turntable for supporting and rotating the three-dimensional load; a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load; and a logistical controller arranged to control rotation of the load and movement of the tape dispenser, wherein the logistical controller controls the operation of the apparatus to bind the load with tape according to a desired pattern; and means for inputting into the logistical controller, one or more values corresponding to one or more selected heights, wherein the logistical controller controls the operation of the apparatus to apply substantially horizontal over-bands over the desired pattern at the one or more selected heights.  
   
   
       20 . The apparatus as defined in  claim 19  wherein the desired pattern applied to the load is a helical pattern comprising a plurality of upward and downward helixes which are spaced from each other with at least some of the upward helixes crossing at least some of the downward helixes  
   
   
       21 . An apparatus for binding a three-dimensional load with tape, the apparatus comprising: 
 a turntable for supporting and rotating the three-dimensional load;    a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load; and    a logistical controller arranged to control rotation of the load and movement of the tape dispenser to dispense tape onto the load in a desired pattern, wherein the controller is programmed to position the tape dispenser at a home position which is at a convenient height for the user to position tape on the load and wherein the controller is arranged to control movement of the tape dispenser to a start position to commence application of tape to the load in the desired pattern.