Abstract:
An integrated stacker for positioning materials in a stack, compressing the stack and positioning and sealing a strap onto itself around the stacked and compressed materials includes a frame, a conveyor mounted to the frame, and a stacking assembly mounted to the frame. The stacking assembly includes a feed for feeding the materials onto the stack. The stacker further includes aligning arms operably connected to the frame for aligning the materials on the stack, a compression section mounted to the frame for compressing the stack of materials and a strapper section mounted to the frame. The strapper section includes a strap chute for conveying the strap around the compressed stack of material, a feed head for tensioning the strap and a welding head for sealing the strap material onto itself. The strap chute defines a strap path. The feed head, welding head and strap chute are mounted to a bracket that is mounted to the frame along a portion of the strap path. The feed head and the welding head are mounted to the bracket independent of each other and are independently installable onto and removable from the bracket.

Description:
BACKGROUND OF THE INVENTION 
     The present invention is directed to a stacker such as that used for stacking papers and the like, which stacker has an integral strapper. More particularly, the present invention is directed to a stacker having an integral strapper with modular head components. 
     Stackers are well known in the art. Typically, a stacker allows for the stacking of, for example, magazines and the like into a stack of such items for easy handling. The stacker conveys the material from a supply into a stacking path. The materials are then stacked onto a rigid element, such as a sized sheet of plywood and onto one another. The stacker assures alignment of the edges of the stacked materials to permit handling efficiency and to reduce the damage that could otherwise occur to the materials. The stacked materials are then compressed and a strap is applied around the materials to secure the stacked and bundled materials into a “log”. 
     In known stackers, the stacker includes, along its length, a location at which a freestanding, fully independent strapping machine can be inserted into the frame. In such an arrangement, the strapping machine is essentially integrated into the stacker for independent operation. In that stackers vary from one manufacturer to another, a variety of strapping machines and/or a single, versatile strapping machine must be configured for insertion into the stacker to integrate with the overall stacking and bundling operation. 
     Although such versatile strapping machines are available and are commonly known, such strapping machines are often relatively heavy, uniquely designed devices. One such versatile strapping machine is currently commercially available from Signode Container Industry Systems, a division of Illinois Tool Works of Glenview, Ill. Such a strapping machine is manufactured to operate with stackers commercially available from Baldwin Stobb (model Nos. VSB-5 and 150-0L) a division of Baldwin Technology Company, Inc. Other stackers for which this strapper is configured include SMC (model Nos. V3600 and V2000), and Civiemme ST Series Stackers commercially available from IMC America, Inc. 
     Reiterating, these stackers which are manufactured by different companies, have different configurations and different strapping machine requirements. For example, each of the stackers includes a conveyor along which the bundled materials are transported. The conveyors move the bundled materials away from the stacker area, which areas are a different angles in different machines. Thus, the strappers must be able to accommodate material stacks at different angles. As such, the strapping machine must be configured so that the chute through which the strap traverses can be adjusted to the angle at which the chute is positioned along the conveyor. 
     Accordingly, there exists a need for a strapping machine that is integrated into a stacker, which the strapping machine is readily configured for mounting without versatility in design. Desirably, such a strapper is integrated into the stacker so that the control system for the strapping machine can likewise be integrated into the control system for the stacker. Most desirably, such a strapping machine includes modular components that can be readily installed on the stacker, which components are interchangeable between like stackers and stacker from different manufacturers. 
     BRIEF SUMMARY OF THE INVENTION 
     An integrated stacker positions materials in a stack, compresses the stack and positions and seals a strap onto itself around the stacked and compressed materials. The stacker includes a frame, a conveyor mounted to the frame and a stacking assembly mounted to the frame. The stacking assembly includes a feed for feeding the materials onto the stack. 
     The stacker includes alignment means mounted to the frame for aligning the materials on the stack and a compression section mounted to the frame for compressing the stack of materials. 
     The stacker includes an integrated strapper section mounted to the frame. The strapper section includes a strap chute for conveying the strap around the compressed stack of material, a feed head for feeding the strap into and through the strap chute and for tensioning the strap and a welding head for sealing the strap material onto itself. The strap chute defines a strap path. 
     The feed head, welding head and strap chute are mounted to a bracket that is mounted to the frame along a portion of the strap path. The feed head and the welding head are mounted to the bracket independent of each other and are independently installable onto and removable from the bracket. 
     In a current stacker, the compression section includes a pair of cylinders each having a compression plate operably mounted thereto. The strap chute is positioned between the cylinders. The strapper section bracket can be mounted to a pair of upright support elements. The bracket defines an opening therein for access of a portion of the feed head and a portion of the welding head to the strap path. The opening can be divided into a first opening for access for the portion of the feed head to the strap path and a second opening for access for the portion of the welding head to the strap path. 
     The stacker can include a control system. Preferably, the control system includes controls for the strapper section. In this manner, the strapper section is fully integrated with the strapper. 
     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 SEVERAL VIEWS OF THE DRAWINGS 
     The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein: 
     FIG. 1 is a schematic side view illustrating a stacker having an integral strapping machine, the stacker being shown with a stack of material in the strapping section of the machine; 
     FIG. 2 is a top view of the stacker of FIG. 1; 
     FIG. 3 is a side view of a stacker similar to that shown in FIG. 1, and showing a strap supply arrangement; 
     FIG. 4 is a front view of the strapper portion of the stacker of FIG. 3, with the strapping section components removed for clarity of illustration; 
     FIG. 5 is a cross-sectional view taken along line  5 — 5  of FIG. 3; and 
     FIG. 6 is a cross-sectional view taken long line  6 — 6  of FIG.  5 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated. 
     It should be further understood that the title of this section of this specification, namely, “Detailed Description Of The Invention”, relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed herein. 
     Referring now to the figures in particular to FIG. 1 there is illustrated, generally, a stacker  10  having an integrated, modular strapping machine or strapper, indicated generally at  12 , embodying the principles of the present invention. The stacker  10  includes a frame  14  having a feed section  16  for feeding the materials M to be stacked and a conveyor  18  along which a stack and/or bundle S of stacked materials is transported. The stacker  10 , as will be recognized by those skilled in the art, includes an elongated stacker chute  20  in which the materials M to be stacked are indexed. The stacker chute  20  is inclined at an angle α relative to the conveyor  18  so that the materials M to be stacked can be “leaned” rearward to remain in the stacked orientation. In known stackers, the angle of incline a varies from about 10 degrees to about 30 degrees. 
     For purposes of the present invention, the materials M to be stacked may be referred to as magazines or the like. However, those skilled in the art will recognize the various items that can be stacked and bundled in such a stacker  10 . FIG. 3 illustrates a similar stacker  10  better showing the stacker frame  14 . The illustrated feed section or assembly  16  is exemplary of those used in known stackers  10 . 
     Referring briefly to FIG. 6, alongside of the stacker chute  20 , the stacker  10  includes a pair of arms  22   a,b  mounted to pivoting posts  24   a,b  that swing the arms  22   a,b  inward toward the stack S to assure that the edges of the stacked materials M are aligned. Alignment of the materials M facilitates handling and further reduces the damage that may otherwise occur to the materials M. 
     Referring again to FIG. 1, subsequent to stacking a desired volume of material M, a rigid element B is placed on top of the material stack S. Such an element B, for example, a plywood board, is typically sized so that it is about the same size as the materials M that are stacked. For purposes of reference, a similar rigid element B is placed on the bottom of the stack S so that the stacked material is essentially “sandwiched” between the rigid elements B. 
     After stacking and alignment of the materials M, and placement of the rigid element B on the top of the stack S, the stack S is compressed. To carry out such compression, the stacker  10  includes (typically) a pair of cylinders  26   a,b  that have compression plates  28   a,b  at and an end of a shaft  30   a,b  extending from the cylinder  26   a,b . The cylinders  26   a,b  are actuated, moving the compression plates  28   a,b  into contact the top rigid element B. The action of the cylinders  26   a,b  against the rigid element B compresses the stack S to a desired compression. 
     The strapping machine  12  is integrated into the stacker  10 , mounted to the stacker frame  14 . The strapping machine  12  includes a strap chute  34  (which defines a strap path  32 ) about which the strap P traverses. The strap chute  34  can be fitted into a notch  36  formed in the frame  14  to assure that it is properly positioned. The strapping machine  12  further includes a feed head  38  and a welding head  40 . For purposes of the present discussion, those skilled in the art will recognize that oftentimes the strapping head is referred to as that assembly that includes both a feed/retract mechanism as well as a weld mechanism. In the present strapping machine  12 , the feed/retract head  38  and the welding head  40  are separate, modular components. 
     Each the feed/retract head  38  (which will be referred to herein as the feed head) and the welding head  40  are separately mounted directly to the stacker frame  14 . That is, these modular components are mounted to the stacker  10  by a mounting bracket  42  that is configured to mount directly to the stacker  10  and to accommodate the modular, “easy on-easy of” mounting of the feed head  38  and welding head  40  to the stacker. 
     As will be understood by those skilled in the art, the strap chute  34  is disposed on the stacker frame  14  between the compression cylinders  26   a,b . In this manner, the strap P is positioned around the material stack S between the two loci of compression on the bundled material M. The feed head  38  and welding head  40  are mounted, again, directly to the stacker frame  14  behind the strap chute  34 . Behind, in this reference, is meant to define the location of the heads  38 ,  40  when looking directly at the front of the strap chute  34 . 
     In a present embodiment, the heads  38 , 40  are mounted to an integrated, universal mounting bracket  42  to support both of the heads  38 ,  40 , independently. The bracket  42  is mounted to a pair of flange brackets  43   a,b  that are, in turn, mounted to a pair of uprights  44   a,b  that extend along and generally parallel to the direction of compression C. The uprights  44   a,b  are part of the overall stacker frame  14 . As such, the strapping section heads  38 ,  40  are directly mounted to the stacker frame  14 . Preferably, a single mounting bracket  42  is used for mounting the feed head  38 , the welding head  40  and the strap chute  34 . This assures proper positioning of the heads  38 ,  40  relative to one another and relative to the strap chute  34  for proper function of the strapper section  12 . 
     To accommodate a single, universal strapper section  12  design, the mounting bracket  42  is configured as a universal bracket that can be installed on (e.g., mounted to) a wide variety of known stackers  10 . To mount the bracket  42  to the stacker  10 , the flange brackets  43   a,b  may be specifically designed for one or more particular stackers, however, each distinct set of flange brackets  43   a,b  is configured to accept the universal mounting bracket  42 . In this manner, a minimum number of specialized parts (i.e., the flange brackets  43   a,b  only) is needed for a single strapper section  12  design. 
     The bracket  42  includes mounting elements  46 ,  48  for the feed head  38  and the welding head  40 . These mounting elements  46 ,  48  permit independently mounting each of the heads  38 ,  40  to the bracket  42  and thus to the stacker  10 . A single opening, as indicated at  50 , can be formed in the bracket  42  to permit operation of both the feed head  38  and the welding head  40 . As will be recognized by those skilled in the art, the opening  50  permits the necessary portions of the feed head  38  and the welding head  40  to be interposed in the strap path  32  (i.e., access to the strap path  32 ) for operating on the strap P. 
     The feed head can include a cutter  54  for severing the strap P to separate the strap P from the strap supply  56  (FIG.  3 ). The illustrated supply  56  permits a substantially constant feed of strap P material to the stacker  10  at a relatively constant tension. 
     Nevertheless, each the feed head  38  and the welding head  40  are independently mounted to the bracket  42 , which in turn is mounted to the strapper frame  14 . This provides a number of advantages over known, independent strapping machines inserted into the stacker. First, space necessary for insertion of an entire strapping machine into the stacker is no longer necessary. This is because the strapping machine components (i.e., the heads  38 ,  40 ) are mounted to the strapper  10 , rather than independently inserted (e.g., wheeled) into stacker. 
     In addition, in strapping machines utilizing an integrated strapping head that includes both the feed head and welding head portions, such strapping heads can weigh in excess of 125 pounds. This weight, in conjunction with the stresses associated with operation of the feed and welding heads, requires considerable structural support for the independent strapping machine. 
     The present arrangement, on the other hand, eliminates these traditional structural elements. Each the feed head  38  and the welding head  40  weigh generally no more than about 30 pounds. As such, the overall weight of components that are supported by the stacker frame  14  is considerably within the structural capabilities of known stackers without modification. 
     Moreover, as will be appreciated by those skilled in the art, the modular design, i.e. separate and independent configuration of the feed head  38  and welding head  40 , provides for relatively fast and easy maintenance of the overall stacker  10 . That is, in the event that maintenance is needed on, for example, the welding head  40 , the stacker  10  can be taken out of service, the welding head  40  removed and if available, a replacement welding head installed on the machine  10  and the machine  10  placed back in service. In that the design of these heads  38 ,  40  is modular, such a replacement operation can be carried out in minutes, rather than hours that may be required in known configurations that utilize separate, e.g., wheeled-in, strapping machines. 
     Furthermore, having a separate feed head  38  and welding head  40  makes stocking or storing spare heads more economically feasible. That is, in an operation that utilizes a number of stackers  10  (even if different stackers are used) a single spare feed head  38  and a single spare welding head  40  (interchangeable between different stacker manufacturers&#39; machines) can be maintained in inventory or stores for use in the event of malfunction or required maintenance. In that the integrated components of the strapping section  12  in the stacker  10  is intended for functioning with a wide variety of stackers  10 , it makes economical “sense” to keep spare heads  38 ,  40  in inventory. 
     To facilitate integrating overall operation of the stacker  10  (including the strapper section  12 ), the electrical components for the strapper section  12  of the stacker  10  can be integrated into the overall control system  52  for the stacker  10  such overall integration is readily carried out with any of the known stackers  10  and it is anticipated that such integration will be able to be carried out with new generations and models of stackers that come available in the market in the future. Such an integration is readily carried out by incorporating the necessary hardware and software for carrying out strapper section  12  operating steps, and other controls and functions into the stacker  10  in an operation that is essentially downstream of the stacking operation. As such, the strapping operation, although integrated into a single machine, is carried out as a downstream function independent of the stacking function. The single integrated controller  52  can be configured with all of the necessary control and monitoring components and functions. 
     All patents referred to herein, are hereby incorporated herein by reference whether or not specifically do so within the text of this disclosure. 
     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. 
     From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.