Abstract:
A device forms and applies an edge protector to a corner of a load as strap is positioned and tensioned around the load, to position the edge protector between the strap and the load. The device includes a shuttle movable between a home position away from the load and an application position near the load. The shuttle includes a breaker assembly having a fixed portion and a movable portion. The movable portion is movable between a position in which it is generally planar with the fixed portion and another position in which it is transverse to the fixed portion. The breaker assembly includes a shoe that defines a receiving region between the shoe and the fixed and movable portions. The shuttle includes a load contact portion. Movement of the shuttle from the home position moves the movable portion from the first to the second position to fold the edge protector. Further movement of the shuttle and contact of the load contact portion with the load discharges the edge protector for receipt on the load as the strap is positioned and tensioned around the load.

Description:
CROSS-REFERENCE TO RELATED APPLICATION DATA 
       [0001]    This application claims the benefit of and priority to Provisional U.S. Patent Application Ser. No. 62/085,974, filed Dec. 1, 2014, the disclosure of which is incorporated herein in its entirety. 
     
    
     BACKGROUND 
       [0002]    Loads such as lumber and the like can be packaged as a plurality of stacked individual units formed into a 3-dimensional bundle. The bundles are secured by strap that is tensioned and sealed around the bundle. Bundles typically include corner protectors that extend along portions of the edges of the load, between the bundle and the straps that encircle the load and the corner protectors. Corner protectors are flat or planar members that are bent around and secured to the corner of the load. Known corner protectors include polymeric angled elements and fibrous, e.g., cardboard or paperboard elements. 
         [0003]    Kasel, U.S. Pat. No. 5,619,838 discloses an apparatus and method for applying edge protectors that includes edge protector applicator assemblies positioned on a frame on either side of the load. The assemblies include grippers that receive and support flat, board-like edge protectors and laterally move to bring the protectors into proximity with the load. The strap, which is then positioned and tensioned around the load and protectors, folds the edge protectors around the load corners. Tensioning of the strap creates the movement that folds the protectors. 
         [0004]    Kasel, U.S. Pat. No. 7,428,865 discloses a press-type strapping machine in which edge protectors are applied to the corners of loads that are pressed (compressed) and secured with a strap. Here too, corner protectors are brought into contact with the load by grippers and the corner protectors are formed or bent by the strap as it is pulled onto and tensioned around the load. 
         [0005]    While such devices function well, the corner protectors may not properly fold along the edge of the load. As such, the protectors may not seat properly on the load and may be subject to being torn or struck and dislodged from the load. 
         [0006]    Preformed edge protectors are also known. However, the preformed protectors require additional steps in the manufacture of the corner protectors. Moreover, excess space is required to store the preformed protectors both in storage and on a strapping machine, and automated systems to position such protectors on a load are limited. 
         [0007]    Accordingly, there is a need for an apparatus and method to fold and apply corner edge protectors on a load during a strapping operation. Desirably, such an applicator receives a planar edge protector and folds the edge protector to conform to the corner of the load, prior to positioning the protector on the load. More desirably still, the applicator discharges the folded edge protector onto the load as the strap is positioned around the load so that it is pulled by and captured between the strap and load and is secured to the load by the tensioned strap. Still more desirably, the edge protectors can be stored on the strapping machine in a flat state to reduce storage requirements. 
       SUMMARY 
       [0008]    A device for forming and applying an edge protector to a corner of a load works in conjunction with a strapping machine that positions and tensions strap around the load. The device receives an edge protector as a flat element, folds the edge protector to conform to the corner of the load and discharges the folded edge protector onto the load as the strap is positioned around the load. In this manner, the edge protector is pulled by the strap and is captured between the strap and load, and is secured to the load by the strap as it is tensioned and sealed to itself. 
         [0009]    The device includes a shuttle operably movable between a home position distal from the load and an application position proximal the load. The shuttle includes a breaker assembly having a fixed portion and a movable portion. The movable portion is movable between a first position in which it is generally planar with the fixed portion and a second position in which it is generally transverse to the fixed portion. In an embodiment, the movable portion is pivotally mounted to the fixed portion. The breaker assembly includes a shoe and defines a receiving region between the shoe and the fixed and movable portions. The shuttle includes a load contact portion. 
         [0010]    As the shuttle moves off of the home position, the movable portion pivots from the first position to the second position to fold the edge protector to about a 90 degree angle. Further movement of the shuttle and contact of the load contact portion with the load discharges the folded edge protector for receipt on the load. The edge protector is received on the load, between the load and the strap, as the strap is pulled onto the load so that when the strap is tensioned, it secures the folded edge protector on the load. 
         [0011]    In an embodiment, the device includes a support that defines a track. The shuttle is operably mounted to the support and the movable portion includes a track engaging member, such as a roller, that cooperates with the track for pivoting the movable portion from the first position to the second position as the shuttle moves from the home position to the application position. 
         [0012]    The shuttle includes a pusher element, such as a pusher finger, operably connected to the load contact portion to push the edge protector from the receiving region in a direction transverse to a direction of movement of the shuttle along the track when the load contact portion contacts the load. In an embodiment, one or more retention elements hold the edge protector in the receiving region. The retention elements can be, for example, a spring loaded finger, a ramped projection or both. 
         [0013]    The device can include an edge protector magazine for storing a plurality of edge protectors, for example, a stack of edge protectors, separating individual edge protectors from the stack and feeding individual edge protectors to the breaker assembly. In an embodiment, the edge protectors are separated from the stack as they are fed to the breaker assembly. A reciprocating element can be used to push individual edge protectors from the stack to feed the edge protectors to the breaker assembly. In an embodiment, an edge protector magazine can be associated with each breaker assembly. 
         [0014]    A method for forming and applying an edge protector to a corner of a load as strap is pulled onto and tensioned around the load to capture and secure the edge protector between the strap and the load, includes receiving an edge protector in a flat state in a breaker assembly and holding the edge protector in the breaker assembly. The edge protector is conveyed toward the load in a conveying direction, and is folded about 90 degrees to substantially conform to a corner of the load. The edge protector is pushed from the breaker assembly in a direction transverse to the conveying direction as strap is pulled onto and tensioned around the load. In this manner the edge protector is captured between the strap and the load, and is secured to the load by the tensioned strap. 
         [0015]    In a method, folding the edge protector can be carried out during the step of conveying the edge protector toward the load. The method can include carrying the breaker assembly on a shuttle and conveying the shuttle toward the load. The method further includes positioning and tensioning a strap around the load such that the edge protector is captured between the strap and the load and is held against the load by the tensioned strap. Because the edge protector is pushed out of the breaker assembly, when the strap is pulled around the load, it contacts the edge protector and pulls the edge protector onto the load. 
         [0016]    In that the edge protector is formed or bent before it is secured to the load (before the strap pulls the edge protector onto the load), the opportunity for misfeeding the edge protector, for the edge protector to not fold in the proper location or for the edge protector to not sit properly on the corner of the load is greatly reduced if not eliminated. 
         [0017]    It will be apparent that edge protectors can be positioned on any or all of the corners of the load at the same time or essentially the same time, as the strap is positioned, tensioned and secured around the load. During the step of encircling the load with the strap, the folded edge protector can be drawn from the breaker assembly into contact with the load. 
         [0018]    In an embodiment, the edge protector can be temporarily held in the breaker assembly during the steps of conveying and folding the edge protector. The method can further include storing at least two edge protectors, separating one of the edge protectors from the other and feeding the separated edge protector to the breaker assembly. 
         [0019]    These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]      FIG. 1  is a front view of a strapping machine, specifically a lumber press, on which the present apparatus for forming and applying edge protectors can be used; 
           [0021]      FIG. 1A  is a perspective illustration of a load of lumber with a pair of edge protectors on an top/side corners of the load and a band of strap positioned around the lumber and the edge protectors; 
           [0022]      FIG. 2  is a partial front view of the apparatus separate from the lumber press; 
           [0023]      FIG. 3  is a front perspective view of an embodiment of an edge protector applicator assembly, the illustrated assembly being the right-hand side assembly of  FIG. 2 ; 
           [0024]      FIG. 4  is an exploded view of the assembly, the illustrated assembly being the left-hand side assembly of  FIG. 2   
           [0025]      FIG. 5  is a perspective view of an angle breaker assembly, the illustrated assembly being the left-hand side assembly of  FIG. 2 ; 
           [0026]      FIG. 6  is an exploded view of an angle breaker assembly, the illustrated assembly being the right-hand side assembly of  FIG. 2 ; 
           [0027]      FIG. 7  is an exploded view of an example of an edge protector magazine; 
           [0028]      FIG. 8  is a perspective similar to  FIG. 3  showing an edge protector in place in the breaker assembly; 
           [0029]      FIGS. 9A and 9B  are front and rear perspective views of the right-hand side assembly showing the edge protector in place in the breaker assembly prior to folding; 
           [0030]      FIGS. 10A and 10B  are front and rear perspective views of the assembly with the edge protector in place and with the edge protector folded; 
           [0031]      FIGS. 11A and 11B  are front and rear perspective views of the assembly with the edge protector in place and folded, and showing the position of the edge protector when pressed to the load and as the edge protector is ejected from the assembly; 
           [0032]      FIG. 12  is a photograph of a side view of the breaker assembly, showing the spring loaded finger and the ramp projection; 
           [0033]      FIG. 13  is a photograph of a bottom view of the breaker assembly; and 
           [0034]      FIG. 14  is a side view similar to  FIG. 12 , showing the breaker assembly with an edge protector in the receiving region. 
       
    
    
     DETAILED DESCRIPTION 
       [0035]    While the present device and method are susceptible of embodiment in various forms, there is shown in the figures and will hereinafter be described an embodiment of the device with the understanding that the present disclosure is to be considered an exemplification of the device and method and is not intended to be limited to the specific embodiment illustrated and method described. 
         [0036]    Referring to the figures and in particular to  FIG. 1 , there is shown an example of a strapping machine  10 , and as illustrated, a lumber press and strapper. The strapping machine  10  is configured to compress a load L, such as lumber and to position, tension and seal strap S to itself around the load L, with edge protectors E positioned between the strap S and the load L, as illustrated in  FIG. 1A . 
         [0037]    The machine  10  includes a press  12  to compress the load L, and a strapping system  14 , such as that disclosed in Kasel, U.S. Pat. No. 7,428,865, which patent is commonly assigned with the present application and is incorporated herein by reference. The strapping system  14  includes a sealing head  16  that seals the overlapping courses of strapping material S to itself. Those skilled in the art will recognize and appreciate the lumber strapper  10  as well as other strapping devices with which the present edge protector applicator  18  can be used. 
         [0038]    The strapping system  14  positions strap S around the load L, tensions the strap S and seals the strap S to itself Edge protectors E are positioned at the corners C, between the strap S and the load L to protect the load L from damage by the strap S. It will be understood that although the figures show edge protectors E on the top/side corners C of the load L, edge protectors E can be applied to the bottom/side corners of the load L as well. 
         [0039]    The edge protector applicators  18  work in conjunction with the strapping system  14 . The applicators  18  receive an edge protector as a flat element, fold the edge protector to conform to the corner C of the load L and discharge the folded edge protector E onto the load as the strap S is positioned around the load L. In this manner, the edge protector E is pulled by the strap S as the strap S is pulled onto the load L, and is captured between the strap S and load L and is secured to the load L by the tensioned and sealed strap S. 
         [0040]      FIG. 2  illustrates left and right-hand side edge protector applicators  18  and the associated edge protector magazines  20  to store a plurality of edge protectors E and feed individual edge protectors E to their respective applicators  18 . Each applicator  18  includes a support plate  22 , a linear rail  24 , a shuttle  26  and a drive  28 . Each shuttle  26  moves along its rail  24 , driven by its drive  28 , between a position at which an edge protector E is fed to the applicator  18  (an outboard position) and a position at which the edge protector E is brought into contact with the load L and ejected from the applicator  18  (an inboard position). Reference may be made to a single shuttle, however, it will be understood that there are both left- and right-hand shuttles. It will also be appreciated that although the figures show edge protector applicators  18  applying edge protectors E to the top/side corners C of the load L, the applicators can be used to apply edge protectors to the bottom/side corners of the load L as well. 
         [0041]    Referring to  FIGS. 3-6 , in an embodiment, the shuttles  26  move along their rails  24  between the inboard and outboard positions by actuation of the drives  28  which drive threaded or screw drive shafts  30 . The shuttles  26  include a threaded receiver  32  that cooperates with their respective shafts  30  to move the shuttles  26  back and forth along the rails  24 . Sensors  34  mounted to the applicators  18  monitor the positions of the shuttles  26 . In an embodiment, the sensors  34  are mounted to the shuttles  26 . It will, however, be appreciated that various types of drives can be used to move the shuttles  26  and that the sensors  34  can be mounted in a variety of locations and manners to monitor the positions of the shuttles  26 . 
         [0042]    The shuttles  26  include a breaker assembly  36  that is configured to receive an edge protector E in a flat state (see, e.g.,  FIGS. 8 and 9A ) and fold, bend or break the protector E into a corner that is at or about a 90 degrees (see, e.g.,  FIGS. 1A, 10A and 11A ) to conform to the corners C of the load L. It will be understood that the material from which the edge protector is formed, e.g., paperboard or cardboard, will bend or fold and will be deformed, but that it may return, to some minor extent, to its pre-folded shape. As such, the final configuration, prior to being applied to the load and secured by the strap is described as at or about 90 degrees. 
         [0043]    In an embodiment, the breaker assembly  36  includes a fixed member  38 , a movable member  40  and a shoe  42   a,    42   b  (collectively  42 ) associated with each the fixed  38  and movable  40  member. In an embodiment, the fixed and movable members  38 ,  40  are plates and oppose the shoes  42  to define a receiving region  44  for receiving the flat edge protectors E. The receiving region  44  is formed as a recess or channel in which the flat edge protector E is inserted and held. The movable plate  40  is pivotally mounted to the fixed plate  38  by a hinge or pivot  46 . The movable plate is pivotable between about 0 degrees and 90 degrees relative to the fixed plate  38  so that a flat edge protector E is received in the receiving region  44  when the movable plate  40  is in the 0 degree position, and when the movable plate  40  pivots it folds or breaks the edge protector E to about 90 degrees. 
         [0044]    The movable plate  40  includes an arm  48  and a roller  50  extending outwardly and downwardly from a rear thereof that engages a track  52  in the support plate  22 . The track  52  has an angled or sloping edge  54  along which the roller  50  rides. When the shuttle  26  is in the outboard or home position (see,  FIGS. 9A and 9B ), the roller  50  is elevated so that the movable plate  40  is in the 0 degree position. As the shuttle  26  moves off the home position (toward the load or toward the inbound position, see  FIGS. 10A and 10B, and 11A and 11B ), the roller  50  is urged downward which pivots the movable plate  40  to fold or break the edge protector E. 
         [0045]    The breaker assembly  36  includes a pusher assembly  54  to push the edge protector E from the assembly  36  when the folded edge protector E approaches or contacts the load L. The pusher assembly  54  includes a contact arm  56 , a pivot plate  58  and a pusher element  60 , such as the illustrated pusher finger. The pivot plate  58  is mounted to the fixed plate  38  by a pivot pin  62  at an end of the plate  38 . The contact arm  56  is mounted to an end of the pivot plate  58  opposite the pivot  62 . The contact arm  56  extends downwardly so as to contact the load L as the shuttle  26  approaches the load L. The pusher finger  60  is formed on or extends from the pivot plate  58 , through a slotted opening  64  in the pivot plate  58  and is positioned in the breaker assembly receiving region  44 , extending downwardly toward the shoe  42 . As the shuttle  26  moves to the load L, the contact arm  56  contacts the load L, which pivots the pivot plate  58  and moves the pusher finger  60  into the receiving region  44  to push the edge protector E from the receiving region  44 . A spring  66  on the breaker assembly  36  returns the pusher finger  60  to the home position. A slot  68  in the shoe  42  accommodates the pusher finger  60  when in the home position to prevent the finger  60  from interfering with the breaker assembly  36  receiving and securing the edge protector E in the receiving region  44 . 
         [0046]    In an embodiment, the breaker assembly  36  can include one or more retention elements to positively secure the edge protector E in the receiving region  44 . In an embodiment, a spring loaded finger  70  in the fixed plate  38  applies pressure on the edge protector E and holds it against the shoe  42  as the shuttle  26  moves and as the edge protector E is folded. The finger  70  is spring loaded, so that the edge protector E remains in place, but is forced out of the receiving region  44  when the pusher finger  60  exerts sufficient force on the edge protector E to dislodge it from the between the finger  70  and the shoe  42 . The breaker assembly  36  can also include a ramped projection  72  extending into the receiving region  44 . Either or both the spring loaded finger  70  and the ramp  72  can be used to hold the edge protector E in the receiving region as the edge protector E is received in the breaker assembly  36 , folded, and conveyed toward the load L. 
         [0047]    Referring now to  FIGS. 2 and 7  there is shown an embodiment of the magazine assembly  20  for storing a plurality of edge protectors E, such as in a stack K, separating individual edge protectors E from the stack and feeding the separated edge protector E to the breaker assembly  36 . The magazine assembly  20  includes, generally, a storage magazine  74 , a reciprocating feeder  76  and a drive  78 . The storage magazine  74  is configured to store a plurality of flat edge protectors E in, for example, a stack K and to supply edge protectors E to the feeder  76 . The feeder  76  includes a reciprocating plate  80  having a thickness about the same as or slightly less than that of the edge protectors E. A rack gear  82  is mounted to a side of the plate  80  opposite the side that contacts the edge protectors E. Rails  84  mounted to the magazine assembly  20  cooperate with linear bearings  86  mounted to the plate  80  to facilitate the reciprocating movement of the plate  80 . 
         [0048]    In an embodiment, the drive  78  is mounted to the assembly  20  and a drive gear  88  is mounted to the drive  78 . The drive gear  88  is operably connected to the rack gear  82  to provide the reciprocating movement of the plate  80 . 
         [0049]    An opening  90  at the discharge of the magazine  74  is sized to permit only a single edge protector E from being discharged from the magazine  74  at a time. Separation of individual edge protectors E from the stack K is accomplished by cooperation of the feeder plate  80  (which has a thickness about the same as or slightly less than that of the edge protectors E), along with the opening  90  at the bottom of the magazine  74  (which is slightly larger than the thickness of one edge protector E). As such, as the plate  80  reciprocates, it contacts an edge protector E along an edge of the plate  80 . The edge protector E is pushed from the stack K, out through the opening  90  at the discharge of the magazine  74 . As the edge protector E is pushed, it is fed into the receiving region  44  in the breaker assembly  36 , between the fixed/movable members  38 / 40  and the shoe  42 , and is captured and held in the receiving region  44  by the spring loaded finger  70 , the ramp  72  or like holding device. It will be appreciated that while the figures show a magazine assembly  20  and structure to feed edge protectors E from a bottom of the magazine  74  to the breaker assembly  36  (and the bottom of the load L), the magazine assembly  20  and breaker assembly  36  can be configured to supply edge protectors E to an overhead assembly to supply edge protectors E to a location at the top of the load L. 
         [0050]    In operation, a load L is present in the strapping machine  10  and the shuttles  26  are in the home or outboard positions, distal from the load. The magazine assembly drives  78  are actuated and the feeder plates  80  reciprocate to feed edge protectors E into the receiving regions  44  of the breaker assemblies  36 . The edge protectors E are held in place in the breaker assemblies  36  (in the receiving regions  44 ) by the spring loaded fingers  70 , ramps  72  or like holding device. 
         [0051]    The breaker assemblies  38  move out of the home position, along their linear rails  24 , toward the load L. As the breaker assemblies  36  begin to move, the rollers  50  contact the support plate tracks  52  and pivot the movable plates  40  to fold or “break” the edge protectors E. The shuttles  26  continue to move toward the load L. As the shuttles  26  approach the load L, the contact arms  56  contact the load L which pivot the pivot plates  58  and move the pusher fingers  60  into contact with the edge protectors E, which in turn pushes the edge protectors E out of the breaker assemblies&#39; receiving regions  44  in a direction transverse to the movement of the shuttle  26 . In this proximal or application position, the folded edge protectors E are freed from their breaker assemblies  36  so that they can be secured to the load L when the strap is positioned and tensioned around the load L and edge protectors E. Following release of the edge protectors E, the shuttles return to their home or outboard positions. 
         [0052]    Contact of the contact arms  56  with the load L is timed with the strapping machine  10  such that the edge protectors E are pushed from the breaker assemblies  36  as the strap S is drawn around the load L and retracted (to pull the strap S from the strap chute) and as the strap S is tensioned around the load L. The overall timing of the strapping machine  10  and application of the edge protectors E can be carried out using a controller or control system  92  that monitors and controls the function of the machine  10 . In this manner, the edge protectors E are captured by the strap S against the load L and are held in place by the strap S as and in conjunction with tensioning and sealing of the strap S. 
         [0053]    It will be appreciated by those skilled in the art that the relative directional terms such as upper, lower, rearward, forward and the like are for explanatory purposes only and are not intended to limit the scope of the disclosure. 
         [0054]    All patents referred to in the present disclosure, are incorporated herein by reference in their entirety, whether or not specifically done so within the text of this disclosure. 
         [0055]    In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. 
         [0056]    From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present disclosure. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover all such modifications as fall within the scope of the claims.