Rotating multi-clipper platform packaging systems

Apparatus, systems, devices, methods and computer program products configured to provide one or more of the following: improved rotary table or platform packaging systems, improved adhesive (glue) based film seal systems, and/or easier loading or releasing mounting systems of horns, forming collars and/or sprockets.

FIELD OF THE INVENTION

The present invention relates to apparatus, systems, methods and computer program products that stuff or otherwise fill product into casings that enclose products therein.

BACKGROUND OF THE INVENTION

Conventionally, in the production of consumer goods such as, for example, meat or other food products, the food is fed (typically pumped) or stuffed into a casing in a manner that allows the casing to fill with a desired amount of the product. As is well-known, the casings can be a slug-type natural or artificial casing that unwinds, advances, stretches and/or pulls to form the elongate casing over the desired product. Another type of casing is a heat-sealed tubular casing formed by seaming together a thin sheet of flexible material, typically elastomeric and/or polymeric material. U.S. Pat. Nos. 5,085,036 and 5,203,760 describe examples of automated substantially continuous-feed devices suitable for forming sheet material or flat roll stock into tubular film casings. Rotating multi-clipper platform systems, such as the Rota-Clip® high speed packaging systems by Tipper Tie, Apex, N.C., have been used to produce increased quantities of clipped product. See, e.g., U.S. Pat. Nos. 4,821,485; 5,020,298; 5,259,168; 5,471,815; and 5,644,896. The contents of the above referenced patents are hereby incorporated by reference as if recited in full herein.

SUMMARY OF EMBODIMENTS OF THE INVENTION

Some embodiments of the invention are directed to packaging systems. The packaging systems include a rotating platform having a vertical column and a plurality of circumferentially spaced apart clippers mounted to the rotating platform. The platform is configured to concurrently mount a plurality of clippers in respective circumferentially spaced apart clipper stations.

In some embodiments, the platform is configured to releasably interchangeably mount two different sized clippers in the different clipper stations, one of the different sized clippers being configured to output larger clip sizes than the other clipper.

In particular embodiments, the different sized clippers include on-board air supply lines that connect to air supply lines at each clip station of the platform such that, in position, the clippers are in fluid communication with a common pressurized air supply for actuation of the different sized clippers.

The table or platform can be configured to concurrently hold twelve clippers, one in each of twelve clipper stations.

The system may optionally include a split main drive sprocket residing under the rotating platform surrounding the vertical column and a drive system with a chain in communication with the sprocket that rotates the rotating platform at a desired speed. The system may also optionally include first and second vertically stacked and spaced apart plates, each of the plates being split into a plurality of adjacent pieces with a radially extending split line extending between the adjacent pieces.

In some embodiments, the system can include a location sensor in communication with the rotating platform and a frame holding the rotating platform. The system can also include a controller that receives data from the location sensor and automatically moves the rotating platform to a desired longitudinal position based on location data from the sensor and user input selecting a product type and/or size for production.

In some embodiments, the system includes a plurality of circumferentially spaced apart cradles that hold clip spools on the platform. Each cradle holds a respective clip spool with clips in cooperating alignment with a corresponding clipper. Each cradle is configured to allow a clip spool to be inserted into the cradle while a corresponding proximate clipper remains in position.

The system may include fine adjustment screws, one in communication with each of cradles, the fine adjustment screws configured to allow an operator to radially move the cradle into a desired position on the platform. Each cradle can releasably hold two spools side-by-side.

In some particular embodiments, the system can include an automated lubrication system configured to automatically mist or spray lubricant onto the sprocket and/or a chain associated therewith during operation.

In some embodiments, the system can also include a flat roll stock to a tubular covering forming system with a forming collar residing upstream of the rotating platform and an adhesive seal system in communication with the forming system that seals the flat stock in a tubular configuration. The adhesive seal system can include an automatic lifter that lifts one long edge of the covering to allow a nozzle to apply adhesive proximate the lifted long edge to seal the covering into the tubular configuration.

The nozzle can be a self-cleaning nozzle with a heater. The nozzle heater is in communication with a controller and the controller is configured to direct the heater to heat to a sufficient temperature to clean adhesive residue from the nozzle.

The adhesive seal system may include a stationary substantially horizontal extruder that merges into a curvilinear flow path that connects to the nozzle.

The adhesive seal system can include four temperature zones that can be individually controlled for temperature, including a first zone associated with the extruder, a second zone associated with an exit from the extruder, a third zone associated with the curvilinear flow path, and a fourth zone associated with an exit from the curvilinear flow path proximate the nozzle.

The lifter can be configured to automatically move between a home position that is laterally and upwardly away from a centerline of the horn and an operative position whereby the lifter travels downwardly to reside above and proximate the horn and inwardly toward the centerline of the horn.

The adhesive seal system can include a rotating drip tray that resides under the nozzle in a inactive nozzle configuration and that is synchronized to automatically rotate away from under the nozzle when the lifter moves to and/or is in its operative position.

The system can include a product horn residing upstream of the platform and a film drive system in communication with a supply of flat roll-stock film. The film drive system can include two vacuum drives, each having a belt, in communication with a display and a system controller, whereby the display is configured to accept user input to cause the vacuum drives to automatically translate the vacuum drive belts to an operative position to clamp the film against the horn.

The system can include a frame. The system can also include a product horn residing upstream of the platform, a film drive system in communication with a supply of flat roll-stock film and a forming collar residing on the horn in communication with the supply of flat-roll stock. The system can include a tool-less forming collar and horn mount assembly having first and second handles that rotate to force a member against a plate that releasable holds the horn and collar in position and a tool-less horn mounting assembly that holds the horn upstream of the forming collar. The tool-less horn mounting assembly can include first and second blocks that define a substantially cylindrical cavity therebetween. The first and second blocks can be configured to releasably attach together via a handle in communication with a rod that extends through the first and second blocks and clamps the blocks against the horn.

Other embodiments are directed to an adhesive sealing module for a packaging system. The module includes: (a) a stationary-mounted substantially horizontal extruder in communication with a hopper of bulk adhesive; (b) a curvilinear heated conduit having opposing upper and lower end portions, the upper end portion being in fluid communication with an adhesive exit portion of the substantially horizontal extruder; (c) an adhesive dispensing nozzle in fluid communication with and positioned proximate the lower end portion of the heated conduit; (d) a roll of flat sheet stock in communication with a forming collar and a substantially horizontally extending horn configured to form the sheet stock in situ into a substantially tubular shape with open overlapping long edges about the horn; and (e) an automated lifter mechanism in communication with the roll of flat sheet stock downstream of the forming collar. In operation, the lifter mechanism is configured to automatically translate to lift a top one of the overlapping long edges of the sheet stock whereby the adhesive dispensing nozzle automatically dispenses flowable adhesive between the long edges of the formed sheet stock.

The nozzle can be a self-cleaning nozzle that is in communication with a system controller that electronically directs a heater associated with the nozzle to heat to a sufficiently high temperature to melt and release adhesive residue in the nozzle.

Still other embodiments are directed to a computer program product for operating a packaging system with a rotating table having a plurality of circumferentially spaced apart clippers thereon in communication with a horn and flat stock to generally tubular film or covering forming system. The computer program product includes a computer readable storage medium having computer readable program code embodied in the medium. The computer-readable program code including: (a) computer readable program code configured to monitor and adjust temperatures in four different temperature zones associated with an adhesive flow path that terminates into an adhesive dispensing nozzle; and (b) computer readable program code configured to increase, then decrease, temperature of the heating zone proximate the dispensing nozzle to cause the dispensing member to perform a self-cleaning or self-clearing operation, thereby inhibiting clogging of the dispensing nozzle.

Still other embodiments are directed to a computer program product for operating a packaging system with a rotating table having a plurality of circumferentially spaced apart clippers thereon in communication with a horn and flat stock to a generally tubular film or covering forming system. The computer program product includes a computer readable storage medium having computer readable program code embodied in the medium. The computer-readable program code includes computer readable program code configured to programmatically provide recipe-specific position adjustment of the table, the clippers and display of set-up data for operators.

Additional embodiments are directed to clip spool cradles configured to releasably hold and release at least one, typically two, side-by-side clip spools.

Still other embodiments are directed to a packaging system with a product horn having a forming collar thereon and a roll of flat sheet stock in communication with the forming collar and the product horn. The system is configured to form the sheet stock in situ into a substantially tubular shape with open overlapping long edges about the product horn. The system also includes a hot adhesive supply source in communication with a nozzle and an automated lift mechanism configured to automatically lift a top one of the overlapping long edges to allow the adhesive nozzle to move under the lifted long edge and apply sealant between the overlapping long edges.

Still other embodiments are directed to a rotating table holding a plurality of circumferentially spaced apart clippers with each respective clipper having a pair of cooperating clip guide bars with an aperture pattern and a guide slot that mount to the rotating table and cooperate with clipper guides that hold and lock the clipper into a desired one of multiple different radial positions.

Yet other embodiments are directed to a rotating table rotary support table holding a plurality of circumferentially spaced apart clippers with each respective clipper having a radially extendable screw defining a fine radial location/position adjustment member for the clipper.

Additional embodiments are directed to a packaging system that includes an adhesive seal system with an extruder, a dispensing nozzle and an adhesive fluid flow path comprising at least four discrete automatic temperature controlled heat zones.

Some embodiments are directed to a packaging system with a rotating table with a vertical column, the table having a plurality of circumferentially spaced apart clippers in fluid communication with a pressurized air supply and air preparation units and a split sprocket surrounding the vertical column in communication with a drive system for rotating the table at a desired speed.

The table can be configured to releasably mount different sized clippers, one that applies larger clips than the other, and wherein the system air supply and air preparation units allow for rapid actuation of the different clippers at a rate of about 300 pieces per minute or 300 feet/min of film to thereby provide substantially the same operational output irrespective of the clipper used.

Some embodiments are directed to a packaging system that includes a horn with a forming collar and a tool-less forming collar assembly support shoulder attached to a frame of the packaging system. The tool-less forming collar assembly includes a support plate with a semi-circular cavity and at least one user-accessible handle attached to the support plate, the at least one handle in communication with a laterally translating member that locks the horn in a substantially horizontal orientation.

Yet other embodiments are directed to a rotating table with a plurality of circumferentially spaced apart clippers. The table is in communication with a sprocket and chain. The table further includes an automated sprocket lubricator sprayer system that is configured to automatically spray or mist lubrication onto the sprocket and/or chain at defined intervals and/or after a predetermined number of rotations of the table.

Additional embodiments are directed to packaging systems with a plurality of cooperating different drive systems. The system includes: (a) a rotating table holding a plurality of circumferentially spaced apart clippers, the rotating table in communication with a table drive system with a selectable rotation speed; (b) a film drive assembly having a film drive system in communication with a supply of flat roll stock film having a selectable speed, the film drive assembly residing upstream of the rotating table with clippers; (c) an adhesive seal system in communication with the film drive system and residing upstream of the table with the clippers, the adhesive seal system having an extruder with an extruder drive system with a selectable extrusion speed in communication with an adhesive flow path that terminates into an adhesive nozzle; and (d) an automated control system in communication with the table drive system, the film drive system and the extruder drive system, configured to synchronize operation, adjust drive speed of one or more of the drive systems during operation of the packaging system and adjust each drive system to operate at a defined speed to cooperate to produce a desired product.

The system may include a horn with an exit portion that ejects filling into lengths of sealed casing. The automated control system is configured to adjust a speed of at least one drive system responsive to force exerted against a dancer arm positioned between the rotating table and the exit portion of the horn so as to be in communication with tensioned filled sealed covering.

Yet other embodiments are directed to a packaging system with a horn that terminates at an end portion proximate a pump interface into a horn collar and pump to horn interface block that releasably holds the horn in sealed fluid communication with the pump.

The horn collar and horn may be held to the system frame by a tool-less horn mount assembly with the block having an upper and lower block member that hold the horn therebetween and attach and release with a user-accessible handle.

Additional embodiments are directed to methods of packaging lengths of products using a packaging system with a multi-clipper rotating table, that include at least one of the following steps, typically a plurality of the steps, and may be carried out using all of the following steps:

(a) accepting user input on a display to select a desired product and/or recipe for production, (b) electronically determining desired operating parameters using based on the user input; (c) electronically determining a longitudinal position of the rotating table; (d) automatically translating the rotating table to a desired longitudinal position based on the selected product or recipe; (e) accepting user input to cause film drives to close against a product horn; (f) electronically monitoring temperatures in an adhesive flow path and adjusting heating zone temperatures to remain within desired operational ranges; (g) electronically directing an adhesive nozzle in communication with the adhesive flow path to carry out a self-cleaning operation; (h) electronically directing a lubricant to mist or spray onto a chain or sprocket associated with a drive system for the rotating table; (i) automatically lifting a top long edge of overlying film layers, then electronically directing the nozzle to advance to dispense adhesive between the overlying film layers; (j) electronically accessing an operating system and/or controller of the system from a remote location using a computer network; (k) electronically synchronizing different drive systems of the system to cooperate at appropriate speeds, including the synchronization of a film drive, an adhesive extruder drive, and the rotating table drive; and (l) replacing one or more spools of clips on the table using a drop in cradle that releasably holds the clip spools.

Although described above with respect to method aspects of embodiments of the present invention, it will be understood that these features may also be embodied as systems, sub-systems, modules and/or computer program products.

These and other objects and/or aspects of the present invention are explained in detail in the specification set forth below.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention will now be described more fully hereinafter with reference to the accompanying figures, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like numbers refer to like elements throughout. Features described with respect to one embodiment may be used alone or with another embodiment although not specifically described with respect to that other embodiment.

In the figures, certain layers, components or features may be exaggerated for clarity, and broken lines illustrate optional features or operations unless specified otherwise. In addition, the sequence of operations (or steps) is not limited to the order presented in the claims unless specifically indicated otherwise. Where used, the terms “attached”, “connected”, “contacting”, “coupling” and the like, can mean either directly or indirectly, unless stated otherwise. The term “concurrently” means that the operations are carried out substantially simultaneously.

The term “frame” means a generally skeletal structure used to support one or more assemblies, modules and/or components. The frame can be a floor mount frame. The term “automated” means that operations can be carried out substantially without manual assistance, typically using programmatically directed control systems and electrical and/or mechanical devices. The term semi-automatic means that operator input or assistance may be used but that most operations are carried out automatically using electromechanical devices and programmatically directed control systems.

In the description of embodiments of the present invention that follows, certain terms are employed to refer to the positional relationship of certain structures relative to other structures. As used herein, the term “front” or “forward” and derivatives thereof refer to the general or primary direction that the filler or product travels in a production line to form an encased product; this term is intended to be synonymous with the term “downstream,” which is often used in manufacturing or material flow environments to indicate that certain material traveling or being acted upon is farther along in that process than other material. Conversely, the terms “rearward” and “upstream” and derivatives thereof refer to the directions opposite, respectively, the forward and downstream directions.

The terms “adhesive” or “glue” means a material that when applied to a seam or overlying edge portions of a covering or casing material can adhere the edges to seal the product (typically in a substantially tubular or elongate shape). The seal is typically strong and is able to withstand desired pressures. For food products, the adhesive can be biocompatible. Examples of suitable adhesives include, but are not limited to, polymers such as melted HDPE (high density polyethylene).

Embodiments of the present invention are particularly suitable for producing encased products that cooperate with clippers to apply clips to seal products held in the casings. The product may be a linked chain of elongated extruded product held in a casing. The casing or covering can be any suitable material or materials (edible or inedible, natural or synthetic) such as, but not limited to, collagen, cellulose, elastomeric, polymeric and/or plastic casing. The term “film” refers to a thin flexible sheet of covering material. When used with food products, the film, casing or covering should be food-compatible.

Referring now to the figures, the system10(FIG. 1) includes a rotating platform20with a table top21with circumferentially spaced apart clippers22(typically double clippers). The system may also include a flowable adhesive fluid delivery path30, a horn52and a forming collar50. As is well known to those of skill in the art, the forming collar50is configured to form sealed (seamed) substantially tubular casings from an elastomeric and/or polymeric sheet and/or planar roll stock that is then stuffed or filled with flowable product. More typically, the roll stock is an elastomeric and/or polymeric sheet that is relatively thin. The roll stock can be flat sheet stock of a flexible film that can be formed in situ into a continuous length of heat-sealed and/or otherwise joined or seamed tubular casing. The forming can be carried out substantially automatically and continuously over a desired interval (typically between at least about 45-60 minutes, depending on the size of the length of the roll stock). The seaming can be performed using a hot-melt flowable material, such as a polymer, as the adhesive that seals two layers together. The seaming can use additional and/or other suitable sealing means, including, for example, ultrasonic, light (ultraviolet or other desired wavelength), chemical, and/or other sealing means. The seam can be a flat seam, a fin seam, or other overlapping and/or abutting joint configuration, but is typically formed with one long edge62of the casing60overlapping the other as shown, for example, inFIG. 21.

The encased elongated or tubular product can be an elongated food product, such as a meat product. Exemplary meat products include, but are not limited to, strands of meat (that may comprise pepperoni, poultry, and/or beef or other desired meat), and processed meat products including whole or partial meat mixtures, including sausages, hotdogs, and the like. Other embodiments of the present invention may be directed to seal other types of food (such as cheese) or other product in casing materials. Examples of other products include powders such as granular materials including grain, sugar, sand, explosives and the like or other flowable materials including wet pet food (similar to that held conventionally in cans) or other powder, granular, solid, semi-solid or gelatinous materials. The product may be a packaged in any suitable industry including food, aquaculture, agriculture, environment, chemical, explosives, or other applications.

Turning toFIGS. 1 and 2, an exemplary rotating platform multi-clipper system10is shown. Although shown as including (typically dual) clippers22, not all need be operational during a packaging operation (e.g., alternating ones can be deactivated), or the table20may include other numbers of clippers22, typically between 10-14. Conventional Rota-Clip® systems are available from Tipper Tie, Apex, N.C. The number of clippers22used in combination with the circumference of the table20, and/or the radially adjusted position of the clippers22on the table20can allow for different lengths of end product to be produced. For example, for the same clipper radial positions, one operation using all 12 clippers22can produce a six-inch product and if every other clipper22is deactivated, up to a 36 inch product can be used. Larger sizes can be achieved using alternate configurations. As shown inFIGS. 1 and 2, the system10can include miniature ball valves22v, typically one for each clipper22in communication with a pneumatic control that automatically controls the activation and deactivation of the respective clipper22based on the system (HMI/PLC) controller10c. As with conventional rotating platform clippers, in operation, the sealed filled tubular covering is clipped under the platform table surface.

As shown inFIGS. 1 and 2, there are two air lines22athat run down the center column12for each clipper station22s. One line is the main air line for the trigger valve underneath the sprocket83(FIG. 10). The second air line allows the clipper gate of the respective clipper22to close. It also has an inline shut off valve22vinstalled in the tubing. If this is used, it shuts off the air to the gate cylinder on that individual clipper. If the gate does not close the clipper will not “fire” (send down the punch or fire the knife). The reason behind turning off a clipper is to run a longer product than the normal length of product (e.g., chub) each clipper can handle. For example, if clipper #1is on, clipper #2is off, and clipper #3is on, the product length becomes the distance from the #1clipper to the #3clipper.

This activation/deactivation status can be based on the “recipe” selected by a user during set-up. The term “recipe” means that the system10can be preloaded, programmed and/or configured with a plurality of different operating conditions and/or configurations based on the desired output. The system10can accept user input to select the desired product and the system can automatically electronically implement different parameters such as different drive speeds, table position, extruder speed, desired clipper activation pattern such as, for example, clipper nos.1,3,5. . .11, clipper nos.2,4,6,8,10,12, or clipper nos.1-12, and the like used based on a pre-defined “recipe” that can generate the desired output.

The user input can be a list or blocks on a display with visual indicia of product types, names and/or desired product length. The system can define the related operational parameters to achieve this output based on the recipe. The recipe may be size- and/or product-specific. For example, a user can select the desired pre-defined product and/or a product size, and the system can be configured to select or identify proper longitudinal position of the platform20with respect to the output feed support surface55(shown as comprising rollers) and/or select the drive speed of certain components, the temperature of the heat zones (e.g., A-D), correct radial pin hole position to use for mounting the clippers22to the platform20, and the like, based on a defined “recipe”. Thus, for example, the recipe can be programmed and configured to include an electronic library and/or look-up table of clipper position (e.g., which pin aperture number to use on the clip mounting slide bar and clip guides), which can be visually displayed for an operator and can also automatically activate the desired clippers22and select the platform20rotation speed, the covering draw speed (e.g., film or casing), temperatures for one or more of the zones A-D, and the adhesive extruder speed.

The rotating platform or table20can be in communication with an improved air supply and air preparation system20a(FIG. 2) for actuation of the clippers so that the systems10can operate with interchangeable size clippers22and associated clips to provide improved speed, manufacturing adaptation, and/or provide the same operational output (e.g., 300 pieces per minute) irrespective of the size of the clipper22used.

In some embodiments, the table20can accept different sized clippers22, such as a “100” series clipper available from Tipper Tie, Inc., Apex, N.C. and a “200” series clipper available from Tipper Tie, Inc., Apex, N.C. The 100 series can have a 100T clip size and the 200 series clipper can operate with a Z200 clip size. The 100 series clip sizes (smaller clipper) is normally used for products having about a 0.75 inch diameter to about a 1½ inch diameter. The 200 series (larger clipper) is normally used for product sizes up to about 3½ inch in diameter. The clip size for a particular product can be selected based upon film material thickness. In the past, two different machines were required, one for each clipper size. The larger old model clipper (200 series) required more air to run it at its maximum speed. The machine could run 300 feet of film per minute, but because of the air consumption of the large valves on the 200 series clippers, it slowed down the maximum number of pieces to 140 pieces per minute. Embodiments of the present invention employ a larger air supply system and allow for interchangeable use of the different size clippers in a manner that does not require that the machine maximum output be slowed to accommodate the larger clipper. Embodiments of the system10can run either set of clippers on the one machine at a speed of about 300 feet of film per minute.

The system10can have an air system that can run the larger clippers (200 series) at the same rate as the old systems could run the smaller clippers (100 series). That is, the system10can operate at a rate that is either about 300 pieces/minute or a maximum of about 300 feet of film/minute, “whichever comes first”. To further explain the term “whichever comes first”: the speed of the overall machine can be determined in feet of film/minute produced. The smaller length and smaller diameter products can sometimes pump faster than large ones. For example, an 8 inch long×1 inch diameter piece or “chub” of product can be pumped and produced faster than a 18 inch long chub×3 inch in diameter. Embodiments of the present invention can produce 300 pieces/minute as long as they are 12 inch and under. Pump speeds can vary for each client's facility. The system can produce about 300 feet of film/minute irrespective of the clipper size in use.

The rotating platform20has a vertical support12(also described as a column or leg) which is in communication with the main drive system20dthat rotates the platform and clippers at the desired speed (and can automatically vary the speed depending on production requirements/inputs). The air supply lines that connect to the various clippers can travel down the column12to an air supply. The system10can include a single common main air supply that can be diverted to feed all of the clippers. Alternatively, each or groups of the clippers may have a dedicated discrete air supply. Each clipper22can include on-board air supply conduits/lines with valves that releasably connect to the air supply lines on the column12. The large clippers may have larger valves relative to the smaller clippers but can mount to the platform20using the same mounting hardware and/or mounting configuration as the smaller clippers, including allowing for the same fine and gross position adjustment as will be discussed further below. The air supply can be provided at any desired operating pressure sufficient to run the clippers at a desired speed, typically at a pressure between about 80-125 psi. The large and small clippers can interchangeably attach to the air supply lines at each clipper station on the platform20and the clip air supply lines on the platform can have standardized fittings that interconnect to each type of clipper.

FIG. 2illustrates that the system10can also include a position or location sensor27that may optionally longitudinally translate12dwith the vertical table support12on a sliding platform12p. The sensor27is configured to detect and provide data regarding the position of the forward edge of the frame10erelative to the position of the table20and/or table support12and communicate the position data to the system controller10c, which directs the longitudinal (motorized) drive to cause the vertical table support12to be longitudinally translated to automatically adjust for spacing relative to the discharge feed support55and/or exit end of the horn50. The location sensor27can be an optical sensor(s) that can be configured to optically project substantially horizontally from a location upstream of the frame edge10eas illustrated by the arrows inFIG. 2. The location of the platform20relative to the horn50can be automatically carried out based on a selected “recipe” that is selected for manufacture to help automatically set-up the system for operation. Previous systems employed a hand-crank wheel for movement, which required operator labor and unreliable precision in placement.

FIG. 3illustrates that the discharge feed support surface55includes tension feedback members70,71,72that communicate with the filled tensioned casing/product (not shown). Member70is configured to translate outwardly from a pivoting arm71in response to excess tension, which exerts force against the member70, causing the film speed, the adhesive extrusion speed, and/or adhesion delivery to increase. In operation, the downstream member71is configured to communicate with a position sensor73to provide the feedback to the controller to allow the controller to adjust the operational parameters.

FIG. 4Aillustrates a clip guide23defined by a pair of spaced apart plates23p1,23p2, each having a slot23sformed therein and mounted to the table20across a radially extending gap21gtherebetween. Each of the clip guide plates23pincludes aligned radially spaced apart apertures23athat releasably receive a locking pin23l(FIG. 5) to hold the clipper22in a desired radial position on the table20.FIG. 4Aalso illustrates a cradle25that releasably holds spools of clips28on the table20.FIGS. 4B and 4Cshow an alternate embodiment of the cradle25′ as will be discussed further below. As shown inFIG. 5, the clippers22each include a clip mount24that extends across the gap21gand slides in the slots23s. The clip mount24also includes apertures24athat receive the locking pin23l. An operator can select different apertures24a,23ato define the desired radial position and lock the clipper22into place. The clipper mount24can have fewer apertures24athan the clip guides23, such as between about 2-3 apertures24a, while the clip guides23can have between 5-10, typically about 6, apertures23a.

In some embodiments, as also shown inFIGS. 5 and 6, the system10can include a “fine” radial adjustment screw26. The “fine” radial adjustment screw can allow an operator to adjust the position after a clipper22is locked into a “gross” position using the selected apertures23a,24a. The “fine” adjustment screw26can move the clipper22for even more precise radial position. The fine adjustment screw26can provide for between 0.1 inch to about 1 inch or radial adjustment, but is typically less than the gross adjustment that is obtained using only the gross adjustment mounting positions. The gross adjustment can be provided using a selected pair of cooperating apertures23a,24a(typically allowing for about ⅛ inch radial position changes), while the fine adjustment may be used to “tweak” such a position, typically radially moving the locked-position clipper22less than the gross adjustments, typically by less than ⅛ inch. This fine adjustment can help set substantially exact distances between clippers22and can produce more accurate or reliable product lengths. The system controller10ccan reside in the HMI unit with a display10dfor touchscreen input. Other user-interface and/or inputs can be used.

FIGS. 7-9illustrate easy-release and mount spool cradles25according to embodiments of the present invention. This configuration allows for rapid clip reload as the clipper can remain in position while the clip spool with the clips can be dropped into the cradle25. The cradle25is configured to snugly hold two side-by-side clip spools281,282. As shown inFIG. 8, the cradle25is aligned with and can be mounted to the clipper22and also reside on the surface of the table21. One side of the cradle may span the gap21g. The cradle25can include an upwardly extendable spring126configured to bias the handle125to a retracted configuration that can be lifted upward to allow a clip spool to be easily withdrawn and a different spool dropped straight in as desired. The spring126can be provided as a coil spring or another resiliently configured device that can provide the desired retention force and/or bias. The cradle25can be configured to define two spool holding cavities25cthat snugly receive the respective spool281,282, and that extend radially between an upper and lower (rigid elastomeric) tubular bar,25u25las shown inFIG. 8. The cradle25can include a handle125that can pivot between open and closed positions via pivot125p. The handle125can comprise two lateral top portion extensions (e.g., a “T” shape) to snugly reside against adjacent spool walls of the different clip spools (FIG. 2) to inhibit the spools from “free wheeling”. The cradle25can be configured to hold different size clips (such as the “100” and “200” size clips and associated clippers are available from Tipper Tie, Inc., Apex, N.C.). The spool width for each different clip size can be substantially the same. The cradle25can be configured to radially slide as the clipper mount24slides into the desired clipper mounting location on the platform or table20. As shown the cradle25can include inner wheels25won the outside of the lower bars25lthat reside on the support surface of the table20.

FIGS. 4B and 4Cillustrate another embodiment of the cradle25′. In this embodiment, instead of the wheel25wdiscussed above, the cradle25′ mounts to the table20using a block25band an inner mount25mthat hold the front and back members25i,25oabove the table20and in alignment with adjacent corresponding clippers22. The cradle25′ can translate with the adjustment of the clipper22as discussed herein. The block25bcan engage the slots23sand the front mount25mcan engage a clipper22. As for the embodiment shown inFIG. 4A, the cradle25′ has inner and outer members25i,250that can be radially spaced apart and cooperate to hold a respective clip spool28. The members25i,25ocan be rollers that can mount on an internal rod that extends between and attaches to outer mounts127. The members25i,25ocan reside at substantially the same level (rather than one residing above the other).

FIGS. 10 and 11illustrate a sprocket83and chain drive84in fluid communication with an automated lubrication spray system80that extends from an oil supply85to a nozzle80nthat is directed to spray the teeth of the sprocket83and/or the chain84as the chain contacts the sprocket83. The system10can be configured to automatically activate the sprayer nozzle80nperiodically (e.g., every 10 minutes or every certain number of revolutions of the table20) and to have the sprayer80nspray or mist the entire perimeter of the sprocket83at least once per activation. The activation is typically programmatically directed based on communication from the system controller. The lubricant spray can be in a fine mist to inhibit pooling of fluid under the system10. A catch tray may be placed between the sprocket and the floor (not shown).

FIG. 12shows that the sprocket83can be a split sprocket. The split sprocket83is typically in two equal pieces83a,83b, but may be in more than two pieces and may not be symmetrically split. The sprocket83can also include spaced apart holes apertures83hthat direct the airlines22afrom each clip station22beneath the sprocket83. The table (vertical) support stand or leg12rotates in response to rotation of the sprocket83, driven by the chain drive84and drive system (e.g., motor). The stacked vertically spaced apart (Support) plates86,87can reside proximate the sprocket83and may also be split plates87a,87b,86a,86b, respectively, to allow for ease of repair without requiring disassembly of the vertical stand12to remove the sprocket83. The split line of the support plates86,87can be aligned, as shown, or offset. The split line of the support plates86,87may be offset with the split line of the sprocket83as shown or may be aligned (not shown). A suitable split sprocket is available from Martin Sprocket and Gears, Inc., located in Mansfield, Tex.

FIG. 13illustrates the fluid adhesive system30with an associated adhesive flow path30f. The flow path30fhas a substantially horizontal first portion associated with the (horizontal) extruder33, which merges into a curvilinear portion associated with a conduit, pipe or hose36that travels up, then down to a delivery head or nozzle39(FIG. 15). The extruder33can be stationary and horizontally oriented which may improve resin feeding from the hopper31into the extruder33relative to a conventionally used vertical extruder. The conduit, pipe or hose36has a lower end proximate the nozzle39that is able to move substantially vertically between about 3-6 inches, typically between about 4-5 inches (down for application or dispensing of the adhesive from the nozzle39and up in a rest configuration).

The heat seal module or system with the fluid adhesive delivery system30can include at least four separately controllable heat zones, shown as “A, B, C, D” inFIG. 13. Individual control allows the system10to electronically monitor and to set different (or the same) temperatures at each zone A-D. Zone A is associated with the barrel33bof the extruder, which includes at least one internal heater, typically two internal heaters. Zone B is associated with the end fitting or exit block34proximate the discharge end of the extruder33. Zone C is associated with the curvilinear conduit36(the conduit can be a hose and/or pipe). Zone D is associated with the end fitting38proximate the lower portion of the conduit36. The end fittings34,38can include heat blocks34b,38bwith a respective heat element attached thereto. The heat blocks can heat conductively based on the heat input through the thermal elements34e,38e, respectively. The heat blocks34b,38bcan be metallic such as SST or brass. As also shown, ropes or other fastening or insulating members can be wrapped around the end portions of the conduit36proximate the heater blocks/end fittings for further structural and/or insulation reinforcement. As shown, rope is looped around the end fittings.

The conduit36can comprise a blanket heater36hthat is configured to provide the desired wattage and is overwrapped with at least one insulation layer, typically comprising Nomex®-fiberglass fibers, but other insulation materials may be used. As shown, the conduit36can include an outer elastomeric sleeve. The conduit36can also include an internal steel or SST tube or other material that defines the inner wall that contacts the flowable adhesive, which may be surrounded with a SST mesh for improving burst pressure (the SST mesh can reside under the insulation layer(s)). Examples of suitable flexible heated hoses include those available from Diebolt and Company, located in Old Lyme, Conn. or Conrad Company, located in Columbus, Ohio. The conduit36can have a length between about 10-80 inches. In the embodiment shown, the conduit36has a length of about 48 inches.

Each of the heaters can be configured to heat the adhesive to or above the melt point, typically between about 200-300 degrees Celsius. All the zones can be heated to the same temperature (typically between about 200-300 degrees Celsius) or each zone can be heated to a different temperature to promote the flow of the adhesive. In some embodiments, the blocks34b,38bmay have a higher target temperature than the extruder33.

The heater38eproximate the nozzle39can be configured to operate at a higher temperature, particularly at start-up (and/or shut down) to provide a self-clearing or self-cleaning nozzle. This is in contrast to conventional systems where operators were required to use a blow-torch or other cleaning method after removing the nozzle from the device to re-configure the nozzle to be ready for subsequent use. The cleaning or clearing temperature can be set to about 225-300 degrees Celsius. The cleaning or clearing operation can be automatically initiated upon start-up of the system10, upon activation of the extruder33and/or by an operator selectable input on the controller or other suitable switch. The temperature of the lower heater zone D can be reduced from the cleaning or clearing temperature once the adhesive flows suitably from the nozzle39. The temperature reduction can be automatic after a defined time or self-cleaning period.

As shown, the system10includes a vertically oriented hopper31that holds bulk adhesive material, typically in solid pellet, crystal or granule form. The adhesive pellets can comprise a polymer such as, for example, HDPE. The hopper31feeds the raw material to a horizontally extending screw extruder33that includes a barrel33bin communication with a screw auger. As shown, the extruder33is stationary and fixed in position. As discussed above, the barrel33bincludes at least one heater, typically two internal heaters, to melt the pellets or other source adhesive material into a flowable form.

The fluid flow system can comprise a pressure sensor that senses the pressure in the extruder barrel33b. The pressure limit can be configured to ensure that the downstream pipe or hose is not over-pressured; typically the pressure limit is set to about 1500 psi and the system10and/or the adhesive system30can be automatically shut down if this pressure is exceeded. A suitable commercially available extruder is a ¾ inch screw extruder from Killion Extruders, located in Cedar Grove, N.J. A keyway or groove can be bored or formed into the inner diameter of the extruder feed section (at about “6:00 o'clock” opposite the infeed of the hopper) to promote flowability of the pellets into the extruder33without over driving the motor.

The nozzle39can be configured to emit a plurality of strips of adhesive onto the surface of the film/covering (60,FIG. 21), typically three strips.

FIGS. 17A and 17Billustrate that the system10can include a tool-less/tool-free mounting configuration153for releasably attaching the forming collar50and horn52to the frame10f. As shown, two rotating handles53can be used to both lock and release a substantially planar vertically oriented mounting plate54in axial position on a forming shoulder plate111attached to the system frame10fand holding two web guide idler rollers125. Once the horn52is in position in the cavity of the shoulder plate111c, the horn52and collar50can be easily locked into position by turning the handles53to force the compression members56toward each other and against the plate54. To release, the handles53can be turned the other way to release the holding force of the members56, allowing a user to be able to remove the horn/collar52/50without requiring any tools. The compression members56can be configured so that one resides on each side of the cavity111c. The compression members56can comprise a forming collar clamp block that cooperates with a respective handle53.

As discussed above, the system10includes a horn52which cooperates with forming and sealing mechanisms to convert flat roll stock material60into substantially tubular seamed covering/casing as the material travels over the forming collar50. The horn52includes an internal flow channel that extends through the horn52. In operation, the flow channel directs product to flow therethrough (sealed from the environment). As the product exits the discharge end of the horn52, it is stuffed into or fills the sealed casing material60that is held around the outer surface of the horn52. The horn52can be positioned in the apparatus10on support structures10fso that it is substantially horizontal with the centerline aligned with upstream and downstream components during operation.

Referring toFIGS. 18A,18B and19, the horn52is in fluid communication with a filler/product pump and supply150located upstream thereof as shown schematically inFIG. 19. The horn52can terminate into a metal mounting collar57that engages a tool-less mounting assembly154located upstream of the forming collar proximate the pump outlet block54configured to seal the collar57to the pump interface58iof the pump pipe58. The tool-less/tool-free horn mount assembly154can include a handle59on a top portion of the block54can be easily turned to lock or release the horn52from the system frame. The block54can be in two cooperating pieces, a top block54tand a bottom block54bwhich form a cylindrical cavity54cthat engages the horn52. The top and bottom blocks54t,54bcan include a vertical slot54sthat hold a clamp screw159that is attached to the handle59. The assembly may also include a flat washer118and a thrust washer115that reside in or proximate a recess54rin the top block54t. The tool-less horn mount assembly154may include two dowel pins116, one on each side of the block54, typically residing at a top portion of the lower block54b. The assembly154may also include a fill horn key117.

FIGS. 20-22illustrate an automated lifting mechanism for lifting one long edge portion of the covering (e.g., film) to allow the adhesive delivery nozzle39(FIG. 15) to advance between the upper and lower layers of overlying covering60, particularly to flip or lift the top layer62up proximate in time to when the conduit36and nozzle39are lowered to an active dispensing position and the adhesive catch tray99(FIG. 20) is also automatically rotated out from under the nozzle39in concert with the lowering of the lifting mechanism and/or lowering of the conduit36into a dispensing mode. As shown, the lifting mechanism90includes a pivoting finger90fthat is pivotably attached to a laterally extending mounting member92via pivot90pand is attached to a linear actuator90a. The mounting member92can be configured to slide on a vertical support member (e.g., tube)93between extended and retracted configurations. As shown, the mounting member92is also attached to a vertically extending actuator96that causes the member to slide up to the rest or home position and down to the operative position on a member93.

In operation, the mounting member92slides down the vertical support member93as the actuator96retracts and the actuator90aextends, causing the finger90fto rotate down and inward toward the covering60, then lift the covering and retract during a short cycle time. Typically, the finger90frotates forward and lifts and/or flips the top covering62, then rotates back within less than about 5 seconds, typically in less than about 1-2 seconds. When the actuator90aretracts, the finger rotates away from the covering60. The member92can remain lowered during dispensing but the finger90fis retracted.FIGS. 20 and 22show the lifting mechanism90in a rest position whileFIG. 21illustrates the lifting mechanism90lowered and the tray99rotated, but with the finger90falready actuated and retracted with the nozzle39between the layers60,62. The system10can include a user input button (e.g., touchscreen on an operator control display or button or switch) to allow an operator to “refire” or extend the finger90fas needed.

The system10can include a Siemens variable frequency drive and integral safety system, including, for example, a Siemens Step7 300 Processor with Integral Safety Systems, including a Siemens touch screen, motor drives and safety modules. The touch screen can include a series of iconic and/or pictorial image display of user-activated or status indicating features for various components, e.g., adhesive nozzle down, pump “on or off” and the like. The electric motors can be explosion-proof TECO motors that can be mounted outside the electrical box to reduce or eliminate cooling issues. The system can include automatic positioning of vacuum belt drives. The system10can be Ethernet ready for remote access via VPN and may also be PROFIBUS ready, foreign language supported.

In some embodiments, the system10can be configured to operate with an automated synchronized drive control system that may use a single virtual axis for ramp-up to maximum operational speed that synchronizes the covering (e.g., film) drive, the adhesive extruder drive and the rotating table drive (using the Siemens or a similar variable frequency drive system). Each drive system can operate at a selected (variable or constant) speed. The film and extrusion drive can operate to provide sealed tubular covering at any desired speed, including between about 10-300 feet per minute, typically between about 150-300 feet/min; more typically, the machine can operate at an operating speed of about 300 feet/minute.

FIGS. 23A and 23Billustrate an example of a film drive assembly200which drives the film60(or other covering) that forms the tubular casing or covering. As shown, there is a belt210that is driven by an electric motor215which drives both vacuum belt drives221,222.

In a typical sequence of events, the forming collar50is placed into position on the horn52by sliding the product horn52through the forming collar50. The forming collar50and product horn52are then placed into position into the tool-less forming shoulder support assembly153(FIGS. 17A,17B). Once the forming collar50is in place, the product horn52can be clamped into position using the tool-less horn mount assembly154(FIGS. 18A,18B). The horn52is clamped, aligning it into position via the vertical pin159in the assembly154(FIG. 18B).

Referring again toFIGS. 23A and 23B, the film drive assembly200has an adjustment wheel225which moves both sets of the vacuum belt drives221,222(together) toward the front or back of the machine. This action allows the front and back vacuum belt drives to be aligned substantially equidistant to the horn52. Once they are equal in distance from the horn52, an input on the touchscreen10d(FIG. 2) can be used to electronically open or close the vacuum drives221,222. The opening and closing are typically simultaneous.

At this point the operator is ready to load film60. Flat roll stock film60is pulled through the forming collar50(which forms a tube around the product horn52). It is pulled past the open vacuum belts221,222down the length of the horn52.

The system10can be configured with an automatic positioning using a touchscreen input on the HMI (human/machine interface) display10d. This user-selectable input tells the vacuum belt drives rear and front221,222of the film drive assembly200, to open or close. After the film60is in position, the machine/system10is ready for operational position whereby the vacuum drives221,222should be closed so that the vacuum belts221b,222babut up against the film60, clamping the film60between the horn52and the belts221b,222b. This can be done pneumatically with air cylinders which are associated with the vacuum belt drive assemblies221,222.

FIG. 24is a block diagram of exemplary embodiments of data processing systems that illustrates systems, methods, and computer program products in accordance with embodiments of the present invention. The processor410communicates with the memory414via an address/data bus448. The processor410can be any commercially available or custom microprocessor. The memory414is representative of the overall hierarchy of memory devices containing the software and data used to implement the functionality of the data processing system. The memory414can include, but is not limited to, the following types of devices: cache, ROM, PROM, EPROM, EEPROM, flash memory, SRAM, and DRAM.

As shown inFIG. 24, the memory414may include several categories of software and data used in the data processing system405: the operating system452; the application programs454; the input/output (I/O) device drivers458; the Automated Control and Drive Module450and/or Recipe Module449: and the data456.

The data456may include a look-up chart of different “recipes” as well as the associated drive speeds, clipper and table position set-up information, and the like, corresponding to particular or target products for one or more producers. The data456may include temperature zone monitoring data to automatically control the temperature in each zone and a synchronized drive module for synchronizing the drive speeds of the different cooperating systems. e.g., film drive system, the table rotation drive system, the extruding speed, pump speed, and the like. The speed of the film/covering60or rotation speed of the table20and the like can be adjusted based on real-time feedback of the operative status of the machine such as from the tension/force feedback from the dancer arm discussed above with respect toFIG. 3. Selection of all, groups and/or individual clippers22can be automated based on the “recipe” to activate or deactivate certain clippers at different (typically alternating) clipper stations, e.g., stations1-12.

As will be appreciated by those of skill in the art, the operating system452may be any operating system suitable for use with a data processing system, such as OS/2, AIX, DOS, OS/390 or System390 from International Business Machines Corporation, Armonk, N.Y., Windows CE, Windows NT, Windows95, Windows98 or Windows2000 from Microsoft Corporation, Redmond, Wash., Unix or Linux or FreeBSD, Palm OS from Palm, Inc., Mac OS from Apple Computer, LabView, or proprietary operating systems. The I/O device drivers458typically include software routines accessed through the operating system452by the application programs454to communicate with devices such as I/O data port(s), data storage456and certain memory414components and/or the dispensing system420. The application programs454are illustrative of the programs that implement the various features of the data processing system405and preferably include at least one application which supports operations according to embodiments of the present invention. Finally, the data456represents the static and dynamic data used by the application programs454, the operating system452, the I/O device drivers458, and other software programs that may reside in the memory414.

While the present invention is illustrated, for example, with reference to the Modules449,450being an application program inFIG. 24, as will be appreciated by those of skill in the art, other configurations may also be utilized while still benefiting from the teachings of the present invention. For example, the Modules449,450may also be incorporated into the operating system452, the I/O device drivers458or other such logical division of the data processing system405. Thus, the present invention should not be construed as limited to the configuration ofFIG. 24, which is intended to encompass any configuration capable of carrying out the operations described herein.

The I/O data port can be used to transfer information between the data processing system405and the downstream clippers or another computer system or a network (e.g., the Internet or Ethernet) or to other devices controlled by the processor. These components may be conventional components such as those used in many conventional data processing systems which may be configured in accordance with the present invention to operate as described herein.

While the present invention is illustrated, for example, with reference to particular divisions of programs, functions and memories, the present invention should not be construed as limited to such logical divisions. Thus, the present invention should not be construed as limited to the configuration ofFIG. 24but is intended to encompass any configuration capable of carrying out the operations described herein.

The operation and sequence of events and can be controlled by a programmable logic controller (PLC). The operational mode and certain input parameters or machine controls can be selected or controlled by an operator input using a Human Machine Interface (HMI) to communicate with the controller as is well known to those of skill in the art.

The block diagram illustrates the architecture, functionality, and operation of possible implementations of embodiments of the present invention. In this regard, each block in the flow charts or block diagrams represents a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that in some alternative implementations, the functions noted in the blocks may occur out of the order noted in the figures. For example, two blocks shown in succession may in fact be executed substantially concurrently or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.

In summary, embodiments of the present invention provide apparatus, systems, devices, methods and computer program products configured to provide one or more of the following features or components: rotating tables with at multiple clippers, typically at least 10, and more typically about 12, circumferentially spaced apart (providing conformance with industry-standard product lengths with minimal or reduced waste); improved flowable adhesive seal systems; clip spool cradles with easy load and release systems; horizontal (typically stationary) extruders in cooperation with curvilinear flow paths and horizontal fill configurations; automated casing (e.g., film) lift members for nozzle insertion between overlapping layers of the casing; an automated table longitude position adjustor extender and retractor; rotary support tables with fine radial clipper location/position adjustments; self-cleaning or self-clearing systems for adhesive delivery nozzles; automated parameter (recipe-specific) position adjustment and displayed set-up data for operators; cooperating clip guide bars with aperture patterns and guide slots that mount to the rotating table and cooperate with clipper guides that hold dual clippers to lock and position the clipper in multiple different radial positions; at least four discrete temperature controlled heat zones in the adhesive fluid flow path: a rotating table with improved air supply and air preparation units for actuation that can operate with interchangeable size clippers and associated clips to provide improved speed or the same operational output (e.g., 300 pieces per minute) irrespective of the clipper used; tool-free releasable mounting of the horn and forming collar; an automated sprocket lubricator sprayer system; automated controls to synchronize the different drive systems of the overall system to cooperate at appropriate speeds, including the synchronization of the film drive, adhesive extruder, and the rotating table drive: an automated drive system speed adjustment based on force exerted against a dancer arm positioned between the table or platform and downstream of the horn and in communication with the tensioned filled film; a split sprocket and split overlying supports positioned about the vertical table mount leg for easier replacement of the sprocket without requiring disassembly of the table/platform; a tool-less releasable horn collar and block that defines a pump interface mounting configuration, and automatic positioning of the vacuum belt drives.