Method and apparatus for stretch wrapping the top and sides of a load

A method and apparatus for wrapping the top and sides of a load. A web dispenser dispenses and stretches web on the direction in which it is dispensed. The load is rotated relative to the web dispenser as web is wrapped onto the load. The web dispenser is positioned in an orientation generally parallel to the sides of the load for wrapping the sides of the load, and is changed to an orientation generally parallel to the top of the load for covering the top of the load. A web supply may change orientation along with the web dispenser or may be fixed relative to the web dispenser in an orientation generally parallel to the sides of the load. When the web supply is fixed, an accumulator is provided for accumulating web. The accumulator dispenses web when the web dispenser is changing orientation and when the web dispenser is in the orientation generally parallel to the top of the load. The web supply does not provide web when the web dispenser is changing orientation or when the web dispenser is in the orientation generally parallel to the top of the load.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates to a packaging apparatus and method for 
covering the top and sides of a load in a stretch wrapping operation. 
2. Description of the Related Art 
Stretch wrapping is a packaging technique in which a web of film is 
dispensed from a film roll. The web is stretched and wrapped around the 
sides of the load to secure, cover and protect the load. It is well known 
in the art to support and maneuver the film roll either manually or 
mechanically. In wrapping the sides of the load, film rolls having a width 
equal to the height of the load can be used to cover the sides of the load 
without the need to vertically maneuver the film roll. Alternatively, a 
lesser width film roll can be vertically maneuvered to spirally wrap the 
film around the sides of the load, thus covering the sides of the load. In 
some instances, the top edge of the film is allowed to extend over the top 
edge of the load and rest on a portion of the top of the load to help 
secure the load. In other instances the film roll is maneuvered manually 
over the top of the load to dispense the film web over a portion of the 
top of the load to tie down and secure the load. 
For some applications, it is desirable to cover not only the sides of the 
load, but also to cover the top of the load as well, to protect the load 
from the adverse effects of water, dirt, dust, and weather. In one known 
method, the top of the load is covered by dispensing a film web from a 
first film roll and wrapping that film web about the sides of the load to 
secure the load. A cover sheet is then dispensed from a second film roll 
and placed over the top of the load with the edges of the cover sheet 
hanging over the sides of the load. Additional film web is then dispensed 
from the first roll and wrapped around the sides of the load to maintain 
the cover sheet in position and further secure the load. 
SUMMARY OF THE INVENTION 
It is an object of the present invention to provide a stretch wrapping 
device which can automatically wrap the top and sides of a load in an 
effective and efficient manner. 
Additional objects and advantages of the invention will be set forth in 
part in the description which follows, and in part will be obvious from 
the description, or may be learned by practice of the invention. The 
objects and advantages of the invention will be realized and obtained by 
means of the elements and combinations particularly pointed out in the 
appended claims. 
To achieve the foregoing objects and in accordance with the purpose of the 
invention, as embodied and broadly described herein, the invention 
includes dispensing a web from a web dispenser, stretching the web along 
the dispensing direction, and wrapping the web around the sides of the 
load by rotating the load relative to the web dispenser while maintaining 
the web dispenser and web being dispensed in an orientation generally 
parallel to the sides of the load. The top of the load is covered with the 
web by repeated steps of raising the web dispenser above the load, 
positioning the web dispenser and web in an orientation generally parallel 
to the top of the load, dispensing web to cover a portion of the top of 
the load with the web, lowering the web dispenser relative to the load, 
and positioning the web dispenser and web being dispensed in an 
orientation generally parallel to the sides of the load, while rotating 
the load relative to the web dispenser. This arrangement allows a single 
web supply and web dispenser to cover the top and sides of the load. 
The present invention also comprises an accumulator for accumulating the 
web when the web dispenser is in the orientation generally parallel to the 
sides of the load, and for dispensing web when the web dispenser is 
changing orientation and is in the orientation generally parallel to the 
top of the load. The accumulator allows the web dispenser to change 
orientation while the film web is supplied from a web supply without the 
film web bunching or binding. 
It is to be understood that both the foregoing general description and the 
following detailed description are exemplary and explanatory only and are 
not restrictive of the invention, as claimed.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Reference will now be made in detail to the presently preferred embodiments 
and methods of the invention, examples of which are illustrated in the 
accompanying drawings. 
According to one aspect of the present invention, the apparatus includes a 
web dispenser for dispensing a web and stretching the web along the 
dispensing direction. Means are provided for positioning the web dispenser 
and alternating the position of the web dispenser and the web between an 
orientation generally parallel to the sides of the load in a lowered 
position for wrapping the sides of the load, and an orientation generally 
parallel to the top of the load in a raised position for wrapping the web 
on the top of the load. Means are provided for rotating the load relative 
to the web dispenser. 
As shown in FIG. 16, web dispenser 12 dispenses web 14 of stretch wrap 
material from film roll 26. Web dispenser 12 includes a frame having end 
plates 16, back plate 18, and a bar 20. Web dispenser 12 also includes a 
clevis 22 rotatably connected to the middle of bar 20 by pivotal 
connection 23, and guide roller 24 rotatably mounted on clevis 22. A film 
roll 26 is mounted on a braked spindle 13 which is supported by end plates 
16. Spindle 13 permits film roll 26 to rotate while braking its motion to 
restrain and stretch web 14 as it is dispensed. 
Alternatively, the web may be stretched by a braked roller, or upstream and 
downstream prestretch rollers which are coupled together so that the 
downstream prestretch roller rotates at a greater speed than the upstream 
prestretch roller and thereby stretches the web in the dispensing 
direction. An example of such a film stretching mechanism is shown in U.S. 
Pat. No. 4,302,920, which is incorporated herein by reference. 
In accordance with the invention, means are provided for positioning the 
web dispenser. The means for positioning the web dispenser preferably 
includes a control system having a programmable logic controller such as 
that shown in FIG. 17 and discussed below. As shown in FIG. 16, the 
positioning means also includes a mechanism for moving the web dispenser 
in accordance with the commands of the control system. The mechanism may 
be hydraulic, pneumatic, electromechanical or similar types of motive 
systems. As shown, the mechanism includes a fluid cylinder 32. One end of 
fluid cylinder 32 is rotatably attached to back plate 18 of web dispenser 
12 at pivot 34. The other end of fluid cylinder 32 is rotatably attached 
to frame 28 at pivot 35. Selective activation of fluid cylinder 32 causes 
the web dispenser 12 to rotate relative to frame 28 about the pivot 37. 
Frame 28 is slidably mounted on mast 70 to be vertically positioned by 
belt 72 which is driven over roller 73 by motor 74. 
In accordance with the invention and as shown in FIG. 13, means are 
provided for rotating load 50 relative to web dispenser 12 whereby load 50 
on pallet 48 is wrapped with web 14. As embodied herein, the means for 
rotating the load includes turntable platform 36, vertical axle 38, 
bearing 40, base 42, drive wheel 44, and motor with geared speed reducer 
46. Platform 36 is supported by drive wheel 44 and casters 44a, and 
pivoted on vertical axle 38 which is journalled on bearing 40 affixed to 
base 42. Motor 46 powers drive wheel 44, which rotates platform 36. The 
means for rotating load relative to the web dispenser may alternatively 
include an arrangement for moving the web dispenser around a stationary 
load. 
A leading end of web 14 is attached to load 50 or a clamp on turntable 36. 
As platform 36 and load 50 is rotated about a vertical axis, relative to 
web dispenser 12, web 14 is dispensed, stretched and wrapped around the 
load. 
As shown in FIG. 1, web 14 is dispensed along vertical sides 51 of load 50 
while web dispenser 12 and web 14 is maintained in a vertical orientation 
generally parallel with sides 51. Sides 51 are spirally wrapped by moving 
dispenser 12 in the vertical direction while rotating load 50. After sides 
51 are wrapped, a sequence is started to wrap the top 53 of load 50. 
As shown in the sequence of FIGS. 2, 3, 4, 5, just after web 14 passes a 
corner 54a of the load 50, dispenser 12 is raised above the top of load 50 
by driving belt 72 with motor 74. Simultaneously, fluid cylinder 32 is 
actuated to change the orientation of web dispenser 12 from a vertical 
orientation generally parallel with sides 51 to a horizontal orientation 
generally parallel with top 53 of load 50. 
As web dispenser 12 is raised, a portion of web 14 engages the corner 54a 
of the load between the side 51a and side 51b of load 50. Web dispenser 12 
continues to be raised and rotated until it is above the top 53 of the 
load 50 and in a horizontal orientation generally parallel to the top 53 
of the load 50. Web dispenser 12 is maintained in this horizontal 
orientation while load 50 continues to rotate, causing the web 14 to 
overlie a portion of top 53 of load 50 and engage the top edge of side 
51b. 
As shown in the sequence of FIGS. 3, 4, 5, dispenser 12 is lowered below 
the top 53 of load 50 after web 14 passes second corner 54b and before it 
passes third corner 54c so that web 14 engages the top edge of side 51c. 
Preferably, at the end of the lowering operation, fluid cylinder 32 is 
actuated to change the orientation of web dispenser 12 from a horizontal 
orientation generally parallel to the top 53 of load 50 to a vertical 
orientation generally parallel to the sides 51 of the load as load 50 
continues to rotate, leaving a flat piece of web covering a portion of top 
53 of load 50 between top edges of sides 51b and 51c. 
As shown in FIG. 5, when web dispenser 12 is lowered below the top 53 of 
load 50 and is in a vertical orientation generally parallel to the sides 
of the load, web 14 is then wrapped around corner 54c of load 50 which is 
diametrically opposite corner 54a. The sequence shown in FIGS. 2-5 is then 
repeated to position a flat piece of web covering a portion of top 53 of 
load between top edge of sides 51d and 51a. The whole procedure continues 
to be repeated, covering adjacent portions of top 53 of the load, until 
the entire top 53 is covered with partially overlapping areas of web as 
shown in FIG. 15. 
The drawings show repeatedly alternating the position of web dispenser 12 
during the raising and lowering steps in which the top of the load is 
covered. However, it is also within the scope of the invention to leave 
web dispenser 12 in the horizontal orientation during the repeated series 
of steps executed while covering the top of the load, and position web 
dispenser 12 in the vertical orientation only when covering the sides of 
the load. 
A second embodiment of the present invention is shown in FIGS. 6-12 to 
illustrate another aspect of the invention. According to this aspect of 
the invention, an accumulator is provided for accumulating the web when 
the web dispenser is in an orientation generally parallel to the sides of 
the load. The accumulator is capable of releasing the accumulated web when 
the web dispenser is changing orientation and in an orientation generally 
parallel to the top of the load. 
In this arrangement, the film roll 126 and the frame 127 supporting film 
roll 126 do not change orientation when web dispenser 112 is rotated. The 
axis of film roll 126 is maintained in a vertical orientation generally 
parallel to sides 51 of load 50 throughout the wrapping operation. 
The frame 127 supporting film roll 126 may be integral with frame 128 
supporting web dispenser 112 and vertically positionable along with frame 
128. Alternatively, the frame for supporting the film roll may be 
completely stationary so that when frame 128 is vertically positioned by a 
motorized belt transport (similar to 72 and 74 of FIG. 16), frame 128 and 
web dispenser 112 is moved relative to frame 127 and film roll 126. 
As shown in FIGS. 11 and 12, the web dispenser 112 includes a frame having 
end plates 116, back plate 118 connecting end plates 116, a bar 120, 
clevis 122 rotatably connected to bar 120 by pivotal connection 123, guide 
roller 124 rotatably mounted on clevis 122. 
In accordance with the invention, an accumulator 152 is provided for 
accumulating web 14. As embodied in FIGS. 11 and 12, accumulator 152 
includes first web guide 156 and second web guide 154. First web guide 156 
comprises a first plurality of rollers 166. Each of the first plurality of 
rollers 166 is rotatably mounted to end plates 116 of web dispenser 112. 
Second web guide 154 comprises a second plurality of rollers 164, each of 
which is rotatably mounted to movable plates 158 which are connected by 
bar 160. Plates 158 slide in grooves defined by bars 159. One end of fluid 
cylinder 162 is connected to 120, and the other end of fluid cylinder is 
connected to bar 160. Actuation of fluid cylinder 162 moves first web 
guide 154 and second web guide 156 away from each other to accumulate 
film. The release of pressure on fluid cylinder 162 allows the film web to 
pull the web guides toward each other and thereby dispense the accumulated 
film. 
The means for positioning the web dispenser 112 and the means for rotating 
the load 150 are substantially similar to those described above and shown 
in the embodiment illustrated in FIGS. 13, 14 and 16. Similar numerals are 
used in FIGS. 11 and 12 to indicate parts similar to those shown in the 
embodiment of FIGS. 13, 14 and 16 which are not discussed in detail. 
The method of wrapping load 150 is shown in FIGS. 6-10. Load 150 is placed 
on platform 36. Web 114 is passed through the first plurality of rollers 
166 and the second plurality of rollers 164 in an undulating pattern shown 
in FIG. 12. The loading end of web 114 is then attached to load 150. 
Platform 136 is rotated about a vertical axis to rotate load 150 relative 
to web dispenser 112. The rotation of load 150 pulls web 114 out of web 
dispenser 112. The web 114 is stretched and wrapped around sides 151 of 
load 150 while web dispenser 112 and web 114 are in a vertical orientation 
generally parallel to the sides 151 of load 150. Fluid cylinder 162 is 
actuated to increase the distance between first guiding means 156 and 
second guiding means 154 when web dispenser 112 and web 114 are in a 
vertical orientation generally parallel to the sides of the load to 
accumulate web within the accumulator 152. Sides 151 are spirally wrapped 
by moving dispenser 112 in the vertical direction while rotating load 150. 
As shown in the sequence of FIGS. 6, 7, 8, dispenser 112 is raised above 
the top of load 150 while fluid cylinders 132 and 162 are simultaneously 
actuated. Fluid cylinder 132 is actuated to change the orientation of web 
dispenser 112 from a vertical orientation generally parallel to the sides 
of the load to a horizontal orientation generally parallel with top 153 of 
load 150. 
The pressure on the fluid cylinder 162 is released to allow the first web 
guide 156 and second web guide 154 to be drawn closer to each other as web 
dispenser 112 begins to change orientation. As the distance lessens 
between the first and second web guide 154 and 156, accumulator 152 will 
begin to dispense web previously accumulated between rollers 164 and 166. 
As web dispenser 112 changes orientation and moves into an orientation 
generally parallel to the top of the load, web is no longer fed from web 
supply 126 to web dispenser 112. When web dispenser 112 is not in an 
orientation generally parallel to the sides of the load, web which is 
dispensed onto the load is not taken from web supply 126, but rather from 
accumulator 152. This prevents binding and bunching of web in web 
dispenser 112, which otherwise would occur when rotating web dispenser 112 
relative to the film roll 126. 
Web dispenser 112 is raised and rotated until it is in a horizontal 
orientation generally parallel to the top of the load. Web dispenser 112 
is maintained in this orientation while the load continues to rotate, 
whereby web 114 will overlie a portion of top 153 of load 150. While web 
114 is overlying a portion of the top of the load 50, the web dispenser 
112 is lowered. Simultaneous with the lowering operation, fluid cylinder 
132 is operated to change the orientation of web dispenser 112 from a 
horizontal orientation generally parallel to top 153 of load 150 to a 
vertical orientation generally parallel to the sides 151 of load 150. 
The stroke of cylinder 162 is timed to extend over the period from when 
dispenser 112 begins to rotate away from its vertical orientation, until 
its return to its vertical orientation after dispensing web over a portion 
of the top 152 of load 150. As a result, rollers 164 and 166 proceed 
toward each other during this period when dispenser 112 is not in a 
vertical orientation, dispensing the film web accumulated between rollers 
164 and 166 and eliminating the need to draw film web from film roll 126 
during this period. 
After dispenser 112 returns to a vertical orientation, the distance between 
rollers 164 and 166 is increased by actuating fluid cylinder 162, thereby 
increasing the amount of web 114 contained in accumulator 152 for use in 
the next iteration. Once dispenser 112 is in a vertical orientation, and 
accumulator 152 begins accumulating film web, film web is once again drawn 
from film roll 126, which has the same vertical orientation as the web 
dispenser when the web dispenser is in the vertical orientation. 
The top of the load may be covered by initially covering a central portion 
of the top of the load and working outward, by covering the outward 
portions of the top of the load and working inward, or by working outward 
on one area and inward on another area of the top, or by other patterns 
and routines. 
In the arrangement shown in FIG. 15, the sides and top of load 50 are shown 
covered with a single web. The sides were first wrapped with overlapping 
layers 80-83. The web dispenser was then lifted above the plane of the top 
of the load at opposing corners of the load to cover the top of the load. 
A central portion of the top of the load was covered initially and then 
portions located outwardly from the central portion were progressively 
covered by overlapping layers of web. First portion 90 of the top is 
covered, then second portion 91, followed by third portion 92. The routine 
continues, covering portions 93-99 in sequential order, until the top of 
the load is covered. 
As shown in FIG. 17, the mechanism for controlling the position of the web 
dispenser preferably includes but is not limited to a control system 
having a programmable logic controller (PLC) 43 such as those made by 
Allen-Bradley. As shown in FIGS. 13 and 14, sensors, such as magnetic 
proximity limit switch 39, can be mounted on base 42. Blocks of steel 41, 
which can be sensed by limit switch 39, and mounted underneath turntable 
platform 36. Limit switch 39 supplies load and turntable position 
information to PLC 43 which in turn controls motor 46, motor 70, fluid 
cylinder 32 and, in the second embodiment, fluid cylinder 162. Preferably, 
the PLC uses an additive time function to position the web in an 
overlapped arrangement on different adjoining portions of the top of the 
load during each subsequent revolution of the load as shown in FIG. 15. 
It will be apparent to those skilled in the art that various modifications 
and variations can be made in the practice of the present invention 
without departing from the scope or spirit of the invention. 
Additional advantages and modifications will readily occur to those skilled 
in the art from consideration of the specification and practice of the 
invention disclosed herein. Therefore, the invention in its broader 
aspects is not limited to the specific details, representative devices, 
and illustrative examples shown and described. It is intended that the 
specification and examples be considered as exemplary only, with the true 
scope and spirit of the general inventive concept being defined by the 
appended claims and their equivalents.