Abstract:
A film-tail clamp, cut, and seal system for use in a wrapping apparatus for wrapping an associated item has an oval track vertically oriented and openable to move into and out of the associated item. A shuttle is configured for movement along an inner periphery of the track. A wrapping material is dispensed from the shuttle for wrapping around the item. A clamp arm, which is movable into and out of a plane defined by the film being wrapped around the item, has a sealing element for contacting and sealing a free end portion of the film onto a portion of the film already wrapped around the item. The clamp arm also has a clamp for securing the film when the film is sealed and has a cutter for cutting the free end portion of the film from the portion sealed onto the film.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of priority of Provisional U.S. Patent Application Ser. No. 61/169,162, filed Apr. 14, 2009, entitled “FILM-TAIL SEALING SYSTEM AND METHOD FOR WRAPPING APPARATUS”. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to a wrapping apparatus and more particularly to a wrapping material tail clamp, cut, and sealing system. 
         [0003]    Many types of items are packaged in roll or coil form. For example, steel and aluminum sheet are often coiled for storage, transport, and handling. Such coils can be up to five to seven feet in diameter. 
         [0004]    In order to protect and preserve the appearance of the steel or aluminum, the coils are typically wrapped with protective material in the form of a film. Such a film can be a single wrap of, for example, a low density polyethylene stretch film. The wrap can also include a fabric or other woven or non-woven material wrapped along with the polyethylene film. 
         [0005]    One known machine for carrying out the wrapping process uses a specifically shaped track to carry a film dispensing shuttle through the eye of the coil, while the coil is slowly rotated on its axis on a set of block rollers. The complete body of the coil is effectively sealed by a cocoon of stretch film. 
         [0006]    Generally, the machine has a heavy-duty, generally oval shaped track that provides the guide for the film-dispensing shuttle that travels around the inside of the track. The track has a hinged end section or track arm that pivots upwardly to open the track so that a lower portion of the track can be moved into the eye of the coil. The track is adjustable in the vertical plane to accommodate different coil diameters. 
         [0007]    The track is typically movable on rails to advance into the eye of the coil. The machine can also be movable transverse to the direction of the track. Such a machine is commercially available from ITW Fleetwood-Signode of Glenview, Ill., under the name CoilMaster. One such wrapping system is described in Albert, et al. published U.S. Patent application, US Publication No. 2008-0168643, which disclosure is incorporated herein by reference. 
         [0008]    The film dispensing shuttle includes one or more tractors and trailers that are designed to drive themselves around the track. The film is provided on the shuttle in rolls that have a finite amount of material wound thereon and as such require periodic replacement. Rolls may have to be replaced during the winding of a coil, or, conversely, a coil wrapping may be completed with film remaining on a roll. In either scenario, there are times when the film may have to be clamped, cut and sealed during the wrapping operation. To prevent the “tail” of the film from hanging from the coil, in known operations the tail is manually tucked into the wound film to prevent the tail from interfering with movement of the shuttle and to prevent unwrapping of the film. Other devices are known that seal the tail to the coil. While this may be effective, there is the opportunity for the film to become loose, thus compromising the integrity of the wrap. 
         [0009]    Accordingly, there is a need for a system and method for clamping, cutting, and sealing the tail of the film. Desirably, such a system can effect this operation while a coil is on the wrapping machine. More desirably, such a system and method secures the film tail coming from the shuttle and prevents the film from slipping and unwrapping from the coil. More desirably still, such a system and method are used to clamp the film between itself and the shuttles, seal the film to the coil, and cut the film between the coil and itself. This holds the film (from the shuttles) at the end of the wrapping cycle to reduce the time and labor required to assure that a subsequent wrapping operation is carried out without undue labor. 
       BRIEF SUMMARY OF THE INVENTION 
       [0010]    A film-tail clamp, cut, and seal system is configured for use in a wrapping apparatus for wrapping an associated item. The wrapping apparatus has an oval track vertically oriented and openable to move into and out of the associated item. The wrapping apparatus includes a shuttle configured for movement along an inner periphery of the track. A wrapping material, such as a film, is dispensed from the shuttle for wrapping around the item. 
         [0011]    The film-tail clamp, cut, and seal system of the wrapping apparatus includes a clamp arm that is movable into and out of a plane defined by the film being wrapped around the item. The clamp arm also has a sealing element for contacting and sealing a free-end portion of the film onto a portion of the film wrapped around the item. The clamp arm includes a clamp for securing the film when the free-end of the film is sealed onto the portion of the film already wrapped around the item. The clamp also includes a cutter for cutting the free-end portion of the film from the portion sealed onto the film wrapped around the item. The clamp secures the film for a subsequent coil wrapping operation. 
         [0012]    A second carriage is present for moving the clamp arm vertically toward and away from the item, within or parallel to the plane defined by the film being wrapped around the item. In addition, a third carriage may move the clamp arm horizontally toward and away from the item, within or parallel to the plane defined by the film being wrapped around the item. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0013]    The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein: 
           [0014]      FIG. 1  is a side view of a wrapping apparatus having a film-tail sealing system in accordance with the principles of the present invention, the sealing system track shown in place in a center of a coil; 
           [0015]      FIG. 2  is an enlarged, partial view of the top of the apparatus of  FIG. 1 ; 
           [0016]      FIG. 3  is a top view of the wrapping apparatus showing the location of the sealing system; 
           [0017]      FIG. 4  is a view longitudinally along the wrapping system into the coil on the wrapping machine, as viewed from the left-hand side of  FIG. 1 ; 
           [0018]      FIG. 5  is a view similar to  FIG. 4  showing the wrapping system arm in the extended position; 
           [0019]      FIG. 6  is a top view of the arm of  FIG. 5 ; and 
           [0020]      FIG. 7  is a view of the arm similar to  FIG. 5  showing the clamp jaw in phantom in the open position and in solid lines in the closed position. 
       
    
    
     DESCRIPTION OF THE INVENTION 
       [0021]    While the present invention is susceptible of embodiment in various forms, there is shown in the figures and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated. 
         [0022]    Referring to the figures and in particular to  FIG. 1 , there is shown a wrapping apparatus or machine  10  having a film-tail sealing system  12  and carrying out a method for film-tail sealing embodying the principles of the present invention. 
         [0023]    The machine  10  includes a track  14  having a generally oval shape. A lower portion  16  of the track  14  is cantilevered when a track arm  18  is open. An end (or the track arm  18 ) of the oval is hinged opposite of the base (with the hinge  20  at about the top of the track  14 ) to permit the track  14  to be opened to move the track into and out of the eye E of the coil C. When closed, the track arm  18  aligns with the lower portion  16  of the track  14 . The inside or inner periphery  15  of the track  14 , thus, defines the substantially continuous track  14 . The track  14  moves up and down to accommodate coils C of different diameters. 
         [0024]    A shuttle  22  is configured for movement along the inner periphery  15  of the track  14  in the direction indicated by the arrow at  24 . The shuttle  22  includes a drive or tractor  26 , and one or more film F dispensing cars or trailers  28  that are pulled along by the tractor  26 . The trailers  28  can dispense polymer films, fabric or like wrapping member, collectively referred to as film or films F. 
         [0025]    The machine  10  can include a change system (not shown) to permit removing the shuttle  22  from the track  14  and replacing the shuttle  22  with a ready, stand-by or replacement shuttle  22  with the track  14  in place in the eye E of the coil C. Such a change system is disclosed in the aforementioned published patent application to Albert et al., US Pub. No. 2008-0168643. 
         [0026]    During coil C change-out, it is necessary to cut the film F and to clamp the film F so as to not “lose” the tail  29  of the film F that is attached to the shuttle  22  when preparing to commence a subsequent wrapping cycle. In addition, a “second” tail (from the coil C) is desirably sealed to the coil C to prevent the film F from unwrapping from the coil C. The present film-tail sealing system  12  effects the cutting, clamping and sealing operations. As illustrated in  FIG. 3 , the system  12  is mounted to the wrapping machine  10  at a side  30  of the machine  10 . A frame  32  is mounted at about the top rail of the machine  10 . A first main carriage  34  is mounted to the frame  32  to move horizontally along the frame  32  toward and away from the coil C (in the same direction of travel as the shuttle). Movement is effected by a main carriage cylinder  36  (such as a hydraulic cylinder). Other drives can be used as will be recognized by those skilled in the art. 
         [0027]    The main or first carriage  34  carries a vertical track  38  and a second (or vertical) carriage  40  moves vertically (up and down) on the vertical track  38 . Movement of the vertical carriage  40  is effected by a vertical carriage cylinder  42 , such as a hydraulic cylinder, but again, other drives can be used as will be recognized by those skilled in the art. 
         [0028]    A clamp track  44  is carried on the vertical (second) carriage  40  and a clamp carriage (also referred to herein as a “third carriage”)  46  moves horizontally along the clamp track  44  into and out of the plane P 14  (see  FIG. 3 ) of the shuttle track  14  (as viewed from the perspective of  FIG. 1 , into and out of the plane of the figure). Essentially, the clamp carriage  46  moves into and out of the path of the film F as it wraps around the coil C. Movement of the clamp carriage  46  is effected by a clamp carriage cylinder  50 , such as a hydraulic cylinder, but again, other drives can be used as will be recognized by those skilled in the art. 
         [0029]    Referring to  FIG. 7 , the clamp carriage  46  is formed as a jaw  52  and has a clamp/cutter/sealer assembly  54  mounted thereto. A portion of the clamp/cutter/sealer assembly  54  is carried on a clamp arm  56  that pivots as seen in  FIG. 7  between an open state (the clamp arm  56  pivoted up) and a closed or clamped state (the clamp arm  56  pivoted down). Movement of the clamp arm  56  is effected by a clamp arm cylinder  58 , such as a hydraulic cylinder, but other drives can be used as will be recognized by those skilled in the art. 
         [0030]    A blade  60  within the clamp arm  56  is configured to move (in a reciprocating motion) toward the clamped film F, to cut the film F. Blade  60  movement is effected by blade drive cylinders  62 , such as a pneumatic cylinders or the like. Other drives can be used as will be recognized by those skilled in the art. 
         [0031]    A sealing bar  64  is mounted to the clamp/cutter/sealer assembly  54  adjacent to the clamp arm  56 . The sealing bar  64  is an electric heater element that is used to heat (and seal) the film F onto itself. 
         [0032]    A typical operation sequence is as follow. A wrapping operation has completed—the shuttles  22  are at a home position (as seen in  FIG. 1 ) and the film F is still attached to the shuttles  22  and coil C. The tail sealing system  12  is in the home position with the first main carriage  34  retracted (moved toward the shuttles  22 ), the vertical carriage  40  lowered down and the clamp carriage  46  retracted (away from the coil C). The clamp arm  56  is in the open position. 
         [0033]    The clamp carriage  46  moves inward toward the center of the coil C (as indicated by the arrow at  72 ) so that the film F is disposed within the clamp jaw (with the jaw open). The first main carriage cylinder  36  is actuated to move the first main carriage  34  (and thus the clamp arm  56 ) toward the coil C as indicated by the arrow at  66 . A sensor  68 , such as a photoelectric proximity sensor, located on the clamp/cutter/sealer assembly  54  (in a present embodiment located on the vertical track  38 ) senses when the clamp arm  56  is near to the coil C edge. This also positions the sealing bar  64  at about the edge of the coil C and a limit switch  70  just inside the bore of the coil C (the limit switch  70  is just below the sealing bar  64 ). 
         [0034]    The vertical carriage  40  (the second carriage) moves up until the limit switch contacts the inside edge of the coil C. This positions the sealing bar  64  at the proper location for sealing. 
         [0035]    The first main carriage  34  moves inward toward the coil C so that the sealing bar  64  contacts the coil C (actually contacts the film F on the coil C) and compresses the film-tail  29  on the film F (that is wrapped around the coil C). A pressure transducer (not shown) can be used to determine that a proper pressure is achieved. The clamp arm  56  then closes to hold the film F in the clamp arm  56  and the sealing bar  64  is actuated (current is supplied to the sealing bar  64 ) to seal the film-tail  29  to the film F that is wrapped around the coil C. This seals the tail  29  to the coil C. 
         [0036]    Following sealing of the tail  29  to the coil C, the cutter cylinders  62  are actuated to cut the film-tail  29  from the coil C. The blade  60  is positioned between the sealing bar  64  and the clamp arm  56  so that the wrapped coil C is then separable from clamp arm  56 , but the film F (coming from the shuttles  22 ) remains clamped in the clamp arm  56 . 
         [0037]    The main carriage  34  retracts (moves away from the coil C), the vertical carriage  40  lowers down and the clamp carriage  46  moves of the plane of the machine track  14 . The coil C can then be removed from the wrapping machine  10  and a new coil C placed in the machine  10  for wrapping. It will be appreciated that the film F has remained clamped in the clamp arm  56 , and thus the wrapping machine  10  can commence wrapping a new coil C, with the film F secured, to effect proper wrapping of the coil C. Because the film F is held by the clamp arm  56 , the film F will not slip from the coil C as wrapping commences. 
         [0038]    The advantages of the present film-tail clamp, cut, and seal system  12  will be appreciated by those skilled in the art. The seal system  12  secures the free or tail end of the protective film F covering for a coil C of material, such as aluminum or steel sheet, while the coil C is on the wrapping machine  10 . The present system  12  prevents the film F from slipping and unwrapping from the coil C, effectively clamping the film F between the clamp arm  56  and the shuttle  22 , sealing the film F to the coil C, and cutting the film F between the coil C and the clamp arm  56 . Holding the film F (from the shuttle  22 ) at the end of the wrapping cycle reduces the time and labor required to assure that a subsequent wrapping operation is carried out without undue labor. 
         [0039]    All patents referred to herein, are hereby incorporated herein by reference, whether or not specifically done so within the text of this disclosure. 
         [0040]    In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. 
         [0041]    From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover all such modifications as fall within the scope of the claims.