Wrap Removal System

Abstract

A wrap removal system for removing a film wrap from a load on a conveyor, the wrap removal system including an upright support member, a beam coupled to an upper extent of the support member for movement along a height of the support member, a gripper assembly coupled to the beam and operable to engage the film wrap to create a space between the load and the film wrap, and a cutter assembly.

1 . A wrap removal system for removing a film wrap from a load on a conveyor, the wrap removal system comprising:
 an upright support member;   a beam coupled to an upper extent of the support member for movement along a height of the support member;   a gripper assembly coupled to the beam and operable to engage the film wrap to create a space between the load and the film wrap; and   a cutter assembly.   
   
   
       2 . The wrap removal system of  claim 1 , wherein the beam is coupled to the upright support member with a plurality of rollers in a substantially cantilevered arrangement. 
   
   
       3 . The wrap removal system of  claim 1 , and further comprising a sensor coupled to the beam and operable to detect a top of the load. 
   
   
       4 . The wrap removal system of  claim 1 , wherein the cutter assembly includes a pair of cutting mechanisms, the pair of cutting mechanisms including a corresponding a pair of slitter blades. 
   
   
       5 . The wrap removal system of  claim 4 , wherein the pair of slitter blades rotate about substantially parallel axes in opposite directions and overlap to define a cutting area. 
   
   
       6 . The wrap removal system of  claim 5 , wherein a first one of the pair of slitter blades is driven through a first belt by a motor and a second one of the pair of slitter blades is driven by a second belt that is driven by the first belt. 
   
   
       7 . The wrap removal system of  claim 6 , wherein the second belt is configured to frictionally engage the film wrap and pull it towards the cutting area. 
   
   
       8 . The wrap removal system of  claim 1 , and further comprising a track supported by the upright support member, wherein the cutter assembly is movably coupled to the track to travel along a height of the upright support member. 
   
   
       9 . The wrap removal system of  claim 8 , wherein the track is pivotably supported by the upright support member and movable between a first position remote from the load and a second position adjacent the load. 
   
   
       10 . The wrap removal system of  claim 1 , and further comprising a vacuum blower, wherein the gripper assembly includes a vacuum face in fluid communication with the vacuum blower. 
   
   
       11 . The wrap removal system of  claim 10 , and further comprising a valve in fluid communication between the vacuum blower and the gripper assembly, the valve being operable to change between coupling the gripper assembly to an inlet side of the vacuum blower and coupling the gripper assembly to an outlet side of the vacuum blower. 
   
   
       12 . The wrap removal system of  claim 10 , wherein the vacuum face defines a substantially continuous vacuum chamber defined by a peripheral gasket of the vacuum face, and the gripper assembly further includes a plurality of spaced-apart vacuum ducts defining vacuum sub-chambers extending from the vacuum chamber. 
   
   
       13 . The wrap removal system of  claim 12 , wherein the vacuum chamber is fluidly coupled to the vacuum blower through the plurality of vacuum ducts. 
   
   
       14 . The wrap removal system of  claim 13 , wherein each of the plurality of vacuum ducts is substantially cone-shaped, tapering down in diameter away from the vacuum chamber. 
   
   
       15 . The wrap removal system of  claim 1 , wherein the gripper assembly is pivotably coupled to the beam through a pivot arm. 
   
   
       16 . The wrap removal system of  claim 15 , wherein the gripper assembly is pivotably coupled to the pivot arm. 
   
   
       17 . The wrap removal system of  claim 15 , and further comprising an air jet coupled to the pivot arm and operable to direct air at a downward angle between the load and the film wrap. 
   
   
       18 . The wrap removal system of  claim 1 , wherein the gripper assembly is a first gripper assembly operable to selectively engage a forward face of the load, the wrap removal system further comprising a second gripper assembly pivotably coupled to the beam and operable to selectively engage the forward face of the load. 
   
   
       19 . The wrap removal system of  claim 18 , and further comprising a third gripper assembly pivotably coupled to the beam and operable to selectively engage a first lateral face of the load and a fourth gripper assembly pivotably coupled to the beam and operable to selectively engage a second lateral face of the load substantially opposite the first lateral face. 
   
   
       20 . The wrap removal system of  claim 19 , wherein each of the first, second, third, and fourth gripper assemblies is coupled to a vacuum blower through a main header extending through the beam. 
   
   
       21 . The wrap removal system of  claim 1 , wherein the cutter assembly includes a pair of slitter blades defining a downwardly-facing nip therebetween. 
   
   
       22 . A method of removing a film wrap from a load on a conveyor with a wrap removal system, the method comprising:
 engaging the film wrap on a first vertical face of the load adjacent a top edge of the load;   pulling a portion of the film wrap away from the first vertical face of the load;   inserting at least a portion of a cutter assembly between the load and the portion of the film wrap that is pulled away from the first vertical face of the load;   cutting the film wrap with the cutter assembly; and   moving the cutter assembly vertically downward from a first position adjacent the top edge of the load to a second position adjacent a bottom edge of the load to allow separation of the film wrap from the load.   
   
   
       23 . The method of  claim 22 , wherein the cutter assembly includes a first cutting mechanism having a first slitter blade, the method further comprising driving the first slitter blade of the first cutting mechanism with a first belt to rotate in a first direction. 
   
   
       24 . The method of  claim 23 , wherein the cutter assembly includes a second cutting mechanism engaged with the first cutting mechanism, the method further comprising driving a second slitter blade of the second cutting mechanism to rotate in a second direction opposite the first direction. 
   
   
       25 . The method of  claim 24 , wherein the second slitter blade of the second cutting mechanism is driven by a second belt, the method further comprising engaging a portion of the film wrap adjacent the cutter assembly with the second belt, and pulling the engaged portion of the film wrap towards the first and second slitter blades. 
   
   
       26 . The method of  claim 24 , wherein the first belt is frictionally engaged with a second belt of the second cutting mechanism, the method further comprising driving the second belt and the second slitter blade of the second cutting mechanism with the first belt. 
   
   
       27 . The method of  claim 22 , wherein engaging the film wrap on a first vertical face of the load adjacent a top edge of the load includes placing a vacuum face of a gripper assembly onto an outside surface of the film wrap thereby defining a vacuum chamber, and fluidly coupling the vacuum face with an intake side of a vacuum source. 
   
   
       28 . The method of  claim 27 , wherein engaging the film wrap on a first vertical face of the load adjacent a top edge of the load includes pulling air from the vacuum chamber through a plurality of cone-shaped apertures in the vacuum face that taper down in diameter towards the vacuum source. 
   
   
       29 . The method of  claim 27 , and further comprising mechanically clamping a top edge of the film wrap adjacent the top edge of the load with the gripper assembly. 
   
   
       30 . The method of  claim 27 , and further comprising repositioning a valve between the vacuum source and the vacuum chamber to fluidly couple the vacuum chamber with an outlet side of the vacuum source to release the film wrap. 
   
   
       31 . The method of  claim 27 , and further comprising pivoting the gripper assembly relative to the load to pull the film wrap away from the first vertical face of the load. 
   
   
       32 . The method of  claim 31 , and further comprising moving the load on the conveyor during pivoting of the gripper assembly. 
   
   
       33 . The method of  claim 22 , and further comprising engaging the film wrap on a second vertical face of the load and a third vertical face of the load with a pair of side gripper assemblies, both of the second and third vertical faces being adjacent to the first vertical face, the film wrap being retained by at least one of the side gripper assemblies after the film wrap is cut. 
   
   
       34 . The method of  claim 33 , and further comprising feeding the film wrap from at least one of the side gripper assemblies to a disposal system. 
   
   
       35 . The method of  claim 22 , and further comprising directing a flow of air between the load and the film wrap after cutting of the film wrap. 
   
   
       36 . The method of  claim 22 , wherein the cutter assembly includes a first cutting mechanism and a second cutting mechanism, and the method further comprising plunging a portion of the second cutting mechanism into an exterior surface of the film wrap. 
   
   
       37 . A wrap removal system for removing a film wrap from a load on a conveyor, the wrap removal system comprising:
 an upright support member;   an overhead beam coupled to the support member;   a first gripper assembly pivotably coupled to the overhead beam by a pivot arm and movable between a first position remote from the load and a second position adjacent the load, the first gripper assembly including a vacuum face defining a vacuum chamber in fluid communication with a vacuum source and operable to engage the film wrap and pull the film wrap away from the load;   a cutter assembly movable relative to the support member and operable to cut the film wrap to allow separation of the film wrap from the load; and   an air jet coupled to the pivot arm and fluidly coupled to a compressed air source, the air jet being positioned to direct air in between the load and the film wrap.   
   
   
       38 . The wrap removal system of  claim 37 , and further comprising a pneumatic actuator coupled to the pivot arm and operable to move the first gripper assembly between the first position and the second position, the pneumatic actuator being fluidly coupled to the compressed air source. 
   
   
       39 . The wrap removal system of  claim 37 , and further comprising a second gripper assembly pivotably coupled to the overhead beam by a second pivot arm and movable between a first position remote from the load and a second position adjacent the load, the second gripper assembly including a second vacuum face defining a second vacuum chamber in fluid communication with the vacuum source and operable to engage the film wrap and pull the film wrap away from the load, and a second air jet coupled to the second pivot arm and fluidly coupled to the air source, the second air jet being positioned to direct air in between the load and the film wrap. 
   
   
       40 . The wrap removal system of  claim 37 , wherein the cutter assembly is positionable adjacent a leading face of the load between a first side face and a second side face of the load, wherein the air jet is positioned to direct air toward at least one of the first side face and the second side face to push the film wrap away from the cutter assembly. 
   
   
       41 . The wrap removal system of  claim 40 , wherein the load includes a trailing face opposite the leading face, the air jet being positioned to direct air along the first and second side faces of the load towards the trailing face to inflate the wrap. 
   
   
       42 . A method of removing a film wrap from a load on a conveyor with a wrap removal system, the method comprising:
 pulling a portion of the film wrap away from a first vertical face of the load;   rotating a cutter member having a cutter assembly from a retracted position remote from the first vertical face of the load to an extended position adjacent the first vertical face of the load;   engaging the portion of the film wrap that is pulled away from the first vertical face of the load with the cutter assembly;   cutting the film wrap with the cutter assembly to allow separation of the film wrap from the load;   rotating the cutter member from the extended position to the retracted position;   engaging the film wrap adjacent a second vertical face of the load; and   advancing the load along the conveyor away from the film wrap.   
   
   
       43 . The method of  claim 42 , and further comprising moving the cutter assembly vertically downward along a track supported by the cutter member during cutting of the film wrap. 
   
   
       44 . The method of  claim 42 , and further comprising rotating a first slitter blade of the cutter assembly. 
   
   
       45 . The method of  claim 44 , and further comprising rotating a second slitter blade of the cutter assembly that is engaged with the first slitter blade. 
   
   
       46 . The method of  claim 45 , wherein the second slitter blade is driven by a belt, and the method further comprising engaging a surface of the film wrap and pulling the film wrap towards a cutting area between the first and second slitter blades. 
   
   
       47 . The method of  claim 46 , and further comprising plunging a portion of the cutter assembly into an outer surface of the film wrap prior to cutting the film wrap. 
   
   
       48 . A cutter assembly coupled to a pivotable cutter member of a wrap removal system for removing a film wrap from a load on a conveyor, the cutter assembly comprising:
 a first cutting mechanism including a first slitter blade driven by a first belt;   a second cutting mechanism including a second slitter blade driven by a second belt, wherein the second belt is driven by contact with the first belt; and   a motor coupled to the first belt to drive the first belt.   
   
   
       49 . The cutter assembly of  claim 48 , wherein the first belt is wrapped around a pair of horizontally-spaced pulleys, and the second belt is wrapped around a pair of vertically-spaced pulleys. 
   
   
       50 . The cutter assembly of  claim 49 , wherein the pair of vertically-spaced pulleys includes a first pulley having a first diameter and being substantially coaxial with the second slitter blade and a second pulley having a second diameter smaller than the first diameter. 
   
   
       51 . The cutter assembly of  claim 50 , wherein the second diameter is less than about 1 inch. 
   
   
       52 . The cutter assembly of  claim 50 , wherein the second belt contacts the first belt adjacent the first pulley, and the second pulley extends downwardly below the first pulley to define a lowermost point of the cutter assembly. 
   
   
       53 . The cutter assembly of  claim 48 , wherein the first slitter blade and the second slitter blade define a downwardly-facing nip therebetween. 
   
   
       54 . The cutter assembly of  claim 53 , wherein the first and second slitter blades overlap a distance between about 0.03125 inches and about 0.0625 inches. 
   
   
       55 . A gripper assembly coupled to an overhead beam of a wrap removal system for removing a film wrap from a load on a conveyor, the gripper assembly comprising:
 a body;   a vacuum face coupled to the body and including a peripheral gasket capable of defining a substantially continuous vacuum chamber in fluid communication with a vacuum source when pressed against the film wrap; and   a plurality of spaced-apart vacuum ducts in communication with the vacuum chamber and defining a plurality of vacuum sub-chambers.   
   
   
       56 . The gripper assembly of  claim 55 , wherein the vacuum chamber is fluidly coupled to the vacuum source through the plurality of vacuum ducts. 
   
   
       57 . The gripper assembly of  claim 56 , wherein each of the plurality of vacuum ducts is substantially cone-shaped, tapering down in diameter away from the vacuum chamber. 
   
   
       58 . The gripper assembly of  claim 57 , wherein each of the plurality of vacuum ducts has a smallest cross-sectional area substantially equivalent to the area of a circle having a diameter of about 3/32 inches. 
   
   
       59 . The gripper assembly of  claim 56 , wherein each of the plurality of vacuum ducts defines a contact area at the vacuum face that is at least 50 times as large as a smallest cross-sectional area of each of the plurality of vacuum ducts. 
   
   
       60 . The gripper assembly of  claim 56 , wherein the plurality of vacuum ducts defines a sum total contact area that is between about 50 percent and about 75 percent of a total area of the vacuum face. 
   
   
       61 . The gripper assembly of  claim 56 , wherein each of the plurality of vacuum ducts defines a contact area at the vacuum face that is substantially equivalent to the area of a circle having a diameter of about 11/16 inches. 
   
   
       62 . The gripper assembly of  claim 55 , wherein the gripper assembly is pivotably coupled to the overhead beam through a pivot arm. 
   
   
       63 . The gripper assembly of  claim 62 , wherein the gripper assembly is pivotably coupled to the pivot arm. 
   
   
       64 . The gripper assembly of  claim 63 , wherein the gripper assembly is pivotably about a substantially horizontal axis relative to the pivot arm. 
   
   
       65 . The gripper assembly of  claim 55 , wherein the gripper assembly includes at least 100 vacuum ducts. 
   
   
       66 . The gripper assembly of  claim 65 , wherein the gripper assembly includes between about 400 and about 500 vacuum ducts.