Abstract:
An improved bundling method and apparatus is provided for receiving, forming, and holding a desired shape for the bundling of cylindrical objects of various materials through the use of a set of movable links. The method and apparatus use a series of interconnected, predefined lengths of jointed members or links to complete the process of receiving, shaping, and holding a bundle of cylindrical objects in a polygon shaped cross-section such that banding can be applied to the bundle.

Description:
This application claims the benefit of and hereby expressly incorporates by reference U.S. Provisional Application Serial No. 60/144,690, filed on Jul. 20, 1999. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to forming elongated materials in a desired shape for shipping and/or storage, and more particularly, to an improved bundling method and apparatus. The present invention finds particular application in conjunction with the bundling of cylindrical or nearly cylindrical object (e.g., elongated ovalized objects or polygonal objects with greater than 4 sides), and it is described herein with particular reference to cylindrical objects. It is to be appreciated, however, that the present invention is also amenable to other applications. 
     2. Discussion of the Art 
     Bundling methods and apparatus have been used for many years to produce various bundled shapes from a plurality of elongated cylindrical or nearly cylindrical objects. The cylindrical objects are loaded onto a machine and bundled for shipping. Various shapes of bundles have been used and various numbers of cylindrical objects have been included in the bundles. However, prior art bundling methods and apparatus have been replete with problems. 
     One such prior art method involves dumping cylindrical objects onto loosened flexible straps or the like. The straps are then tightened to form a substantially round bundle. This method is problematic because the round bundles formed are not of a uniform dimensions which causes problems in the stacking and shipping of the bundles. Further, the bundles tend to loosen during shipping. 
     Another prior method involves counting and conveying cylindrical objects to an apparatus which then lifts each cylindrical object with a set of carrying arms. Each cylindrical object is then placed in a designated position to form a hexagonal bundle. This method reduces the problems associated with bundles of varying shapes and varying numbers of cylindrical objects. However, a substantial amount of time is required to form each bundle, and the mechanism is very complex. 
     Another prior art method involves dumping or rolling cylindrical objects into a pre-formed bottom portion of a hexagon or other polygon frame. Once the bottom half portion of the hexagon bundle is formed in the half-hexagonal frame, the remainder of the bundle is formed manually by placing the cylindrical objects one by one. This method reduces the overall amount of time required to form each bundle but a significant amount of time and manual labor is still required to form the top portion of each bundle. Furthermore, this operation can be dangerous to those involved in the manual bundle forming process. 
     Another prior art method involves lifting the cylindrical objects using electromagnets. The bundles are capable of being formed one layer at a time. Bundling in this manner decreases the amount of time required to form each bundle and ensures a uniformly shaped bundle and a uniform number of cylindrical objects in each bundle. Nonetheless, the time required to form each bundle is sub-optimal. Further, the cylindrical objects may only be made of ferrous materials. Thus, cylindrical objects made of non-ferrous materials (e.g., copper tubes) are not capable of being lifted by magnetic systems. 
     Therefore, it is desirable to provide an improved bundling method and apparatus that overcomes these problems and others, while providing more advantageous overall results. 
     BRIEF SUMMARY OF THE INVENTION 
     In accordance with the present invention, an improved bundling method and apparatus is provided for minimizing the above mentioned and other disadvantages of the prior art. The improved method and apparatus are associated with receiving, forming, and holding a desired shape for the bundling of cylindrical objects of various materials through the use of a set of movable links. 
     The method and apparatus of the present invention use, in a preferred embodiment, a series of interconnected, predefined lengths of jointed members or links to complete the process of receiving, shaping, and holding a bundle of cylindrical objects in a polygon shaped cross-section such that banding can be applied to the bundle. 
     A main advantage of the present invention resides in the provision of a method and apparatus for bundling multiple elongated objects such as cylindrical objects using one or more sets of interconnected links that move between first and second operative positions. The first position is a loading position where the links are stretched out to receive the objects. The second position is a bundling position wherein the opposite ends of the set of interconnected links are moved adjacent to each other so that the objects shift into the desired polygonal shape, with the flat portions of the bundled objects lying respectively adjacent the links. Of course, the number of links is related to the number of flats on the resulting bundle, with the length of each flat roughly corresponding to the length of each link. 
     Another primary advantage of the present invention is the provision of an improved bundling method and apparatus that requires the minimum amount of repetitive motion to bundle a group of cylindrical objects. 
     A further advantage of the present invention is the provision of an improved bundling method and apparatus that increases the speed at which a bundle may be formed. 
     Another advantage of the present invention over the prior art is the provision of an improved bundling method and apparatus that may be used on ferrous and non-ferrous materials. 
     Still another advantage of the present invention is the provision of an improved bundling method and apparatus that builds bundles in a manner that is not laborious or dangerous. 
     Another advantage of the present invention is the provision of an improved bundling method and apparatus that may be used to create bundles of varying predetermined polygonal shapes when desired. 
     Still other features and benefits of the invention will be apparent to those skilled in the art upon reading and understanding the following detailed description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The structure, operation and advantages of the preferred embodiments of this invention will become further apparent upon consideration of the following description, taken in conjunction with the accompanying drawings. Of course, the drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention. 
     FIG. 1 is a plan view of a bundler apparatus shown in a first or, unbundled position in accordance with the present invention; 
     FIG. 2 is a plan view of a bundler apparatus shown in a second or bundled position in accordance with the present invention; 
     FIG. 3 is a side elevational view of a bundler apparatus formed in accordance with the present invention; 
     FIG. 4 is a cross-sectional end view of the bundler apparatus taken along line  4 — 4  of FIG. 3; 
     FIG. 5 is a cross-sectional end view of the bundler apparatus taken along line  5 — 5  of FIG. 3; 
     FIG. 6 is an end view of the bundler apparatus in accordance with the present invention; 
     FIG. 6 a  illustrates an enlarged portion of FIG. 6; 
     FIG. 7 is a side view of a link stop mechanism in accordance with the present invention; 
     FIGS. 8 a - 8   f  diagrammatically illustrate a set of links formed in accordance with the present invention and use of same in accordance with the method of the present invention to form a bundle of associated objects; 
     FIG. 9 is an end view of a bundler apparatus and a loading and unloading apparatus operatively connected to the bundler apparatus in accordance with the present invention; 
     FIG. 10 a  is a sectional view taken along line A—A of FIG.  11  and shows a bundling apparatus. formed in accordance with a second preferred embodiment; 
     FIG. 10 b  is a partial side of the apparatus of FIG. 10 a;    
     FIG. 11 is a perspective view of a bundler apparatus in accordance with the second preferred embodiment of the present invention; 
     FIG. 12 a  is a cross-sectional view of a bundler apparatus in accordance with a third preferred embodiment of the present invention; and 
     FIG. 12 b  is a side view of the apparatus of FIG. 12 a.   
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings wherein like reference characters represent like elements, the showings are for purposes of illustrating preferred embodiments of the invention only and not for purposes of limiting the same. An improved method and apparatus is provided for receiving, forming, and holding a desired shape for the bundling of cylindrical or nearly cylindrical elongated objects of various materials through the use of links. 
     With reference to FIG.  1 -FIG. 3, a bundler apparatus  10  is shown for securing and bundling cylindrical or like objects  12  (FIG. 3) according to a first preferred embodiment of the present invention. The apparatus  10  includes a frame  14  having a plurality of vertical support plates  16  for securing first and second truck beams  18  and  20 . The bundling material  12  is, upon being loaded onto the apparatus, positioned perpendicularly relative to the first and second truck beams  18  and  20 . Slidably or otherwise movably contained to or positioned on the first truck beam  18  is a first set of trucks including a drive truck  22  and an idle truck  24 . Likewise, a second set of trucks, axially spaced-apart from the first set and including drive truck  26  and idle truck  28 , is slidably or movably contained to or positioned on the second truck beam  20 . 
     A drive shaft  30  is rotatably mounted between sets of flange bearings  32  disposed on the vertical support plates  16 . The drive shaft  30  extends between the truck beams  18  and  20  and is positioned at or near their respective drive ends  18   a  and  20   a . The shaft  30  is additionally supported by another flange bearing  32  disposed on a support arm  34  extending from the frame  14 . With specific reference to FIG. 3, a drive sprocket  36  is mounted to the shaft  30  which is connected to a motor sprocket  38  of a motor  40  by a chain means  42 . 
     With continued reference to FIGS. 1-3, drive end sprockets  44  and  46  are disposed one each at the distal ends of the shaft  30 . At idle ends  18   b  and  20   b , idle end sprockets  48  and  50  are mounted to stub shafts  52  and  54  which are rotatably mounted to the vertical support plates  16  supporting the idle ends  18   b  and  20   b.    
     With additional reference to FIGS. 4 and 5, drive trucks  22  and  26 , disposed on opposite truck beams  18  and  20 , include upper swing bolts  56  and  58  located on the upper sides of truck drive ends  22   a  and  26   a . Idle trucks  24  and  28 , also disposed on opposite truck beams  18  and  20 , include lower swing bolts  60  (not shown) and  62  located on the lower sides of truck drive ends  24   a  and  28   a . A first drive chain  64  interconnects drive truck  22  to idle truck  24  attaching to swing bolts  56  and  60 . One end of the chain  64  attaches to swing bolt  56 . From the swing bolt  56 , the chain  64  engages and wraps around sprocket  44 , passes through or adjacent to the drive truck  22 , and attaches to swing bolt  60 . In a like manner, a second drive chain  66  interconnects drive truck  26  to idle truck  28  attaching to swing bolts  58  and  62 . The chain  66  engages drive sprocket  46  and passes through or adjacent to the.drive truck  26 . Swing bolts  56 - 62  may be used to synchronize the associated trucks and to adjust tension on their respective chains  64  and  66 . 
     Additional swing bolts  67  and  68  provide an attaching means for first idle chain  70  to further interconnect drive truck  22  to idle truck  24 . The chain  70  attaches to swing bolt  67  at one end and swing bolt  68  at another end. The chain  70  passes through or adjacent to idle truck  24  and engagingly around idle sprocket  48 . In a like manner, second idle chain  72  further interconnects drive truck  26  to idle truck  28  by attaching to swing bolts  74  and  76 . The second idle chain  72  passes through or adjacent to idle truck  28  and engagingly around idle sprocket  54 . Again, swing bolts  67 - 76  allow synchronization of the associated trucks and tension adjustments on their respective chains  70  and  72 . 
     With reference back to FIGS. 1 and 2, drive side longitudinal members  73   a , 73   b  are disposed between first trucks  22  and  26  and perpendicular to truck beams  18  and  20 . These members  73   a , 73   b  are connected by cross members  77 . Likewise, idle side longitudinal members  75   a , 75   b  are disposed between second trucks  24  and  28  perpendicular to truck beams  18  and  20  with cross members  81  therebetween. With reference again to FIG. 1, a plurality of opposing link arms  82  and  84  are disposed along the length of the longitudinal members  73   a , 73   b  and  75   a , 75   b . The link arms  82  and  84  extend upward relative to the longitudinal members. 
     With continued reference to FIGS. 1-5 and specific reference to FIG. 6, a set of link members  86  is disposed between each set of opposing link arms  82  and  84 . In the illustrated embodiment, the set of link members  86  includes five individual (preferably identical) primary link members  88  pivotally attached to one another in an end-to-end arrangement with two shorter end or secondary link members  88   a  located on respective opposite ends of the group of primary link members and used for attaching the set of primary link members  88  to link arms  82  and  84 . The secondary link members  88   a  are, themselves, pivotally connected to the adjacent primary link member  88  and also to the adjacent arms  82  and  84 . The secondary link members  88   a  are each preferably approximately ½ the length of the primary link members  88 , and the two secondary link members can, if desired, be replaced with a single link member  88 . The illustrated arrangement of link members  88  is optimal for forming a hexagonal shaped bundle of material  12 . Of course, it should be appreciated that the length and number of link members  88  may be varied and any polygonal shaped bundle of material  12  can be formed in accordance with the present invention. As will become apparent upon reading the following disclosure, the number of links  88 , 88   a  is directly related to the number of flats on the resulting bundle of objects  12 , and the length of the links is directly related to the length of these flats. 
     With continued reference to FIGS. 1-6 and additional reference to FIGS. 6 a  and  7 , the bundling apparatus  10  additionally includes a freestanding motorized adjustable link stop mechanism  90 . The link stop mechanism  90  includes a plurality of tubular vertical support frames  92 ,  94  and  96 . Support frames  92 - 96  (FIG. 6 a ) include tubular guides  98  disposed telescopically within support frames  92 - 96 . The guides  98  each support a member mounting plate  100  in a level position and allow only vertical movement. Each frame  92 - 96  additionally includes a screw jack  102 , 104 , 106 , a scissor jack, or other suitable and convenient means for raising and lowering respective mounting plates  100 . Longitudinal members  108  are mounted across all of the mounting plates  100  with supporting cross members  110  disposed therebetween. A plurality of link stops  112  are mounted to the longitudinal members  108  in line with the link members  86  that between each set of opposing link arms. Link stops  112  consist of two vertical square posts  112   a  and a connecting cross plate  112   b.    
     With specific reference now to FIG. 7, a motorized system is disposed to move screw jacks  102 - 106  up or down in unison. The system includes a motor  114  mounted to the vertical support frame  92  that is located near one end of frame  14 . The motor  114  is connected by a chain and sprocket means  116  to one end of an input shaft  118  of screw jack  102 . At an opposite end, input shaft  118  has a coupling  120  connected to one end of connecting shaft  122 . At an opposite end, connecting shaft  122  has another coupling  120  connected to a second input shaft  124 , that of screw jack  104 . Likewise, input shaft  124  has, at an opposite end, a coupling  120  connected to yet another connecting shaft  126  which connects to input shaft  128  of jack  106  via another coupling  120 . 
     With reference back to FIGS. 1-6, drive trucks  22  and  26  and idle trucks  24  and  28  are positioned away from one another near the distal ends of truck beams  18  and  20  in an unbundled or first operative position (FIG.  1 ). Such positioning also causes opposing link arms  82  and  84  to separate to a position whereby each set of link members  86  is stretched out under tension (see also FIG. 6) and in a position preferably nearly parallel to the truck beams  18  and  20 . The tension created on the set of link members  86  prevents individual link members  88  from pivoting with respect to one another. In this position, the members  88  unitarily act as a single, taught member. 
     Operation of the subject apparatus in accordance with the present invention can be best understood with reference also to FIGS. 8 a - 8   f . Operation begins with the apparatus unloaded and in the unbundled first position (FIG. 1) with each set of link members  86  in a stretched-out position and link stops  112  set to a select height. The associated bundling material  12  is then loaded onto the one or more sets of link members  86  (FIG. 8 a ). The individual objects of the bundling material  12  are generally loaded onto the link members  88  in a single layer or nearly a single layer. Also, the number of objects of the material to be bundled  12  that is placed on the link sets  86  is controlled and equals the number of objects desired in the resulting bundle. 
     After a select, predetermined amount of the bundling material  12  is loaded onto the link members  88  as described, the motor  40  is used to turn drive sprockets  44  and  46  which move drive trucks  22  and  26  and idle trucks  24  and  28  toward one another eventually to the second bundled position (FIGS. 2 and 8 f ). As shown in FIGS. 8 a - 8   f , the action of the drive trucks  22 - 28  causes the plurality of opposing link arms  82  and  84  to simultaneously move toward one another as shown in FIGS. 8 b - 8   e  which eases the tension in each set of link members  86 . This motion of the link arms can be continuous and/or intermittent. As the tension eases, the bundling material  12  begins falling, rolling, or otherwise shifting toward the central link member  88   c  of each set of link members  88 . Also, link members  88  pivot relative to one another with the central link members  88   c  moving vertically downward until coming to rest on link stops  112 . The opposing link arms  82  and  84  continue advancing toward one another until stop blocks extending from the underside of link arms  82  and  84  contact one another or until otherwise halted. Those of ordinary skill in the art will recognize that the height of the link stops can be controlled during the bundle forming process to support the links at any stage of the process and/or to shift the bundling material and help form the load. Once the link arms are moved together as described, the link members  88  form a hexagon shape out of the bundling material  12  which may be banded or otherwise secured for removal from the apparatus. 
     Those of ordinary skill in the art will recognize that the secondary or end links  88   a  of the link set  86 , in the second or bundled position, move into alignment and combine to form a link member that has a length identical or nearly so to the primary links  88 . While this arrangement is preferred, the secondary links  88   a  can be replaced with a single link. It is also contemplated that the secondary links  88   a  be removed altogether, so that in the second operative position, the material  12  is moved into a bundle shape having N sides or flats using only N−1 links, with a horizontal top flat simply held in position by gravity until the material is banded. 
     In the illustrated embodiment, a polygonal bundle having N flats is formed using one or more sets  86  of links comprising N−2 primary links and two secondary links. As noted, the same bundle could be formed using one or more sets of links comprising N primary links  88  or merely N−1 primary links  88 . Of course, the length of the links controls the resulting length of the flats on the bundle. While it is generally preferred to form symmetrical bundles having equal length sides, the length of the links  88  can be varied within a set  86  of links to vary the length of the flats. 
     With reference to FIG. 9, the apparatus  10  additionally includes an optional loading apparatus  150  attached to frame  14 . Loading apparatus  150  includes a first ramp  152  pivotally attached by a shaft  154  and bearings  156 . The loading apparatus  150  also includes a second ramp  158  securely mounted to drive side link arms  82 . First ramp  154  is movably secured to second ramp  158  by means of rollers  160 . Additionally, a stop plate  162  is disposed between the ramps  152  and  158  to adjustably control the loading process. Stop plate  162  is toggled between an open and closed position by a cylinder  164  or other like means. When stop plate  162  is in a closed position, bundling material  112  cannot be loaded onto the sets of link members  86  from.the first ramp  152 . 
     Additionally, a conveyor support frame  166  rests on the longitudinal members  108 . The support frame  166  includes a pair of length members  168  disposed along the entire length of the longitudinal members  108  and cross members  170  extending therebetween. The support frame  166  supportably secures a conventional conveyor  172  along its length for removing bundling material  12  from the apparatus  10  upon bundling. The entire support frame  166  is capable of being raised and lowered by means of multiple air bag type cylinders  174  or the like. The raising and lowering of the support frame  166  is guided by a plurality of large diameter shoulder bolts  176  which are connected to the support frame  166  and mounting plates  178 . 
     In loading the apparatus  10 , cylindrical objects or other bundling materials  12  are loaded onto the first ramp  152  through any known means. The individual objects of bundling material  12  are allowed to roll down the first ramp  152  until reaching the stop plate  162  which is initially set in the up position. With the apparatus  10  in the unloaded position (links  88  stretched), the stop plate  162  is lowered allowing bundling material  12  to roll down the second ramp  150  onto the stretched links  88  which are acting as a single, taught member as described above. 
     With the bundling material  12  loaded onto the links  88 , the apparatus  10  operates in the manner described above to form a bundle which may then be banded for removal from the apparatus. From the bundled position, the link arms  82  and  84  are moved outwardly away from one another to an intermediate position to relax the hold on the banded bundling material  12  but not far enough for the links  88  to lift the bundling material  12 . The air bag cylinders  174  are then operated to raise the powered conveyor  172  which, in turn, raises the bundling material  12  off of links  88 . The conveyor  172  is then activated to move the bundled material  12  longitudinally off of the bundling apparatus  10  for further handling. After the bundling material  12  is clear of the apparatus  10 , the powered conveyor  172  is stopped and lowered by releasing the air pressure from the air bag cylinders  174 . 
     With reference to FIGS. 10 a - 10   b  and  11 , a second preferred embodiment of the bundling apparatus  10  is shown. In this embodiment, link arms  82  and  84  are mounted to support plates  202  which are slidably mounted to transverse members  204  by tubes  206 . More specifically, tubes  206  include bushings  208  for slidably engaging transverse members  204 . The transverse members  204  are positioned perpendicular to bundling material  12  and are mounted to frame  14  by a plurality of mounting blocks  210 . Longitudinal members  212  continue to connect the plurality of link arms  82  to one another and likewise with the plurality of link arms  84 . The operation is the same as described in the first preferred embodiment except the link arms  82  and  84  are moved via tubes, rather than trucks. 
     With reference to FIGS. 12 a  and  12   b , a third preferred embodiment of the bundling apparatus  10  is shown. In this embodiment, a rotating action is applied to the links arms  82  and  84  to form and hold a bundle of cylindrical objects  12 . The link arms  82  and  84  are rotatably mounted to counter-rotating shafts  250  and  252 . The shafts  250  and  252  are supported on pillow block bearings  254  which are mounted to a frame  256 . The operation is the same as described in the first preferred embodiment except the link arms  82  and  84  are moved via counter-rotating shafts  250  and  252 , rather than trucks. 
     The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they are within the scope of the appended claims or the equivalents thereof.