Abstract:
A film wrapping machine or apparatus wherein various operational conditions and data can be detected, determined, and subsequently utilized for diagnostic, operational performance, and safety characteristics, as well as for implementing improvements in operational performance so as to not only achieve optimal or predetermined performance characteristics but to also achieve economical usage of the wrapping or packaging film.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to film wrapping machines or apparatus, and more particularly to a film wrapping machine or apparatus wherein various operational conditions and data can be detected, determined, and subsequently utilized for diagnostic, operational performance, and safety characteristics, as well as for implementing improvements in operational performance so as to not only achieve optimal or predetermined performance characteristics but to also achieve economical usage of the wrapping or packaging film. 
       BACKGROUND OF THE INVENTION 
       [0002]    Film dispensing and wrapping or packaging machines or apparatus, for wrapping articles, packages, or palletized loads within wrapping or packaging film, are of course well known in the art. Examples of such film dispensing and wrapping or packaging machines or apparatus are disclosed within U.S. Pat. No. 6,195,961 which issued to Turfan on Mar. 6, 2001, U.S. Pat. No. 5,787,691 which issued to Turfan on Aug. 4, 1998, U.S. Pat. No. 5,517,807 which issued to Morantz on May 21, 1996, and U.S. Pat. No. 4,587,796 which issued to Haloila on May 13, 1986. In addition, or in conjunction with the aforenoted patented disclosures, it is known that there are several different types of conventional film dispensing and wrapping or packaging machines. Briefly, for example, a turntable type film dispensing and wrapping or packaging machine is disclosed within  FIG. 1  and is generally indicated by the reference character  100 . In accordance with such a turntable type film dispensing and wrapping or packaging machine  100 , a palletized load, not shown, is adapted to be placed upon a turntable  102 , and a wrapping or packaging film dispensing carriage assembly  104  is movably mounted in a vertically reciprocable manner upon an upstanding standard or support mast  106 . Accordingly, as the palletized load is rotated around the rotary axis of the turntable  102 , and as the wrapping or packaging film dispensing carriage assembly  104  is moved in a vertically reciprocable manner, either from its uppermost position to its lowermost position, or from its lowermost position to its uppermost position, the wrapping or packaging film, dispensed from the wrapping or packaging film dispensing carriage assembly  104 , wraps or packages the palletized load within the wrapping or packaging film. 
         [0003]    Continuing further, a rotary arm type film wrapping or packaging machine is disclosed within  FIG. 2  and is generally indicated by the reference character  200 . In accordance with such a rotary arm type film dispensing and wrapping or packaging machine  200 , an upstanding framework  202  effectively defines a film wrapping or packaging station  204  at an axially central portion thereof, and a palletized load, not shown, which is to be wrapped or packaged within film wrapping or packaging material, is adapted to be disposed at such film wrapping or packaging station  204 . A rotary arm assembly  206 , which is rotatably mounted upon an upper frame member  208  of the upstanding framework  202 , is adapted to rotate around the film wrapping or packaging station  204 , and a wrapping or packaging film dispensing carriage assembly  210  is movably mounted in a vertically reciprocable manner upon the rotary arm assembly  206 . Accordingly, as the rotary arm assembly  206  is rotated around the film wrapping or packaging station  204 , and as the wrapping or packaging film dispensing carriage assembly  210  is moved in a vertically reciprocable manner, either from its uppermost position to its lowermost position, or from its lowermost position to its uppermost position, the wrapping or packaging film, dispensed from the wrapping or packaging film dispensing carriage assembly  210 , wraps or packages the palletized load within the wrapping or packaging film. 
         [0004]    Lastly, a rotary ring type film wrapping or packaging machine is disclosed within  FIG. 3  and is generally indicated by the reference character  300 . In accordance with such a rotary ring type film dispensing and wrapping or packaging machine  300 , an upstanding framework  302  effectively defines a film wrapping or packaging station  304  at an axially central portion thereof, and a palletized load, not shown, which is to be wrapped or packaged within film wrapping or packaging material, is adapted to be disposed at such film wrapping or packaging station  304 . A rotary ring member  306  is rotatably mounted upon a frame member  308  so as to rotate around the film wrapping or packaging station  304 , and the frame member  308  is adapted to be movably mounted in a vertically reciprocable manner upon the upstanding framework  302 . In addition, a wrapping or packaging film dispensing carriage assembly, not shown, is adapted to be fixedly mounted upon the rotary ring member  306 . Accordingly, as the rotary ring member  306  is rotated around the film wrapping or packaging station  304 , and as the frame member  308  is moved in a vertically reciprocable manner, either from its uppermost position to its lowermost position, or from its lowermost position to its uppermost position, the wrapping or packaging film, dispensed from the wrapping or packaging film dispensing carriage assembly, wraps or packages the palletized load within the wrapping or packaging film. 
         [0005]    Regardless of which type of conventional film wrapping or packaging machine is utilized to wrap or package palletized loads within wrapping or packaging film, one desirable operative objective of a film wrapping or packaging operation or procedure is to be able to determine, for example, how much force or tension is being impressed upon the wrapping film, and in conjunction with such, it is desirable to effectively confirm that the force or tension which the wrapping film is actually experiencing corresponds to the desired film force or tension predeterminedly inputted into the apparatus as an operative output characteristic. Another operative objective which one may want to know or monitor in connection with film wrapping apparatus is how much pre-stretch is being impressed upon the wrapping film so as to in fact be capable of achieving a predetermined amount of pre-stretch within the wrapping film. Still another operative objective which one may want to know or monitor, in connection with film wrapping apparatus, is how much wrapping film is in fact being used, for example, per wrapped load, or the number of loads that can be wrapped per roll of wrapping film. Ultimately, the capability of monitoring and knowing the aforenoted operative features or characteristics can lead to the optimal operation of the film wrapping apparatus or system. Still yet further, it is also desirable to incorporate within film wrapping apparatus or systems various operational maintenance or safety mechanisms which can effectively inform operator personnel that, for example, the amount of wrapping film remaining upon a particular roll of wrapping film mounted upon the wrapping or packaging film dispensing carriage assembly is running low, that the door, covering the film drive rollers and normally disposed in a CLOSED and LOCKED position for the protection of operator personnel, is actually OPEN and therefore the apparatus could be operating in an unsafe mode, or that the mandrel or spindle, upon which the roll of wrapping film is disposed, is disposed at an OPEN or LOADING position which would also effectively place the apparatus in an unsafe operating mode. No prior art of which applicants are aware provide all of the various aforenoted operative features or characteristics. 
         [0006]    A need therefore exists in the art for a new and improved film dispensing and wrapping system or apparatus wherein the various aforenoted operative features or characteristics are able to be determined, monitored, and controlled so as to achieve optimal film wrapping operations to be performed by means of the film dispensing and wrapping systems or apparatus, and to ensure that the system or apparatus is in fact being operated in a safe mode of operation for the protection of operator personnel. 
       SUMMARY OF THE INVENTION 
       [0007]    The foregoing and other objectives are achieved in accordance with the teachings and principles of the present invention through the provision of a new and improved film dispensing and wrapping system or apparatus wherein a wrapping or packaging film dispensing carriage assembly is provided with a pair of drive rollers which are driven at different speeds by means of a drive motor and a belt-and-pulley drive system so as to impart a predetermined amount of pre-stretch to the wrapping or packaging film. An infeed target roller and an infeed pinch roller are operatively associated with the pair of drive rollers and are provided upon the infeed side of the pair of drive rollers, and an outfeed target roller and an outfeed pinch roller are also operatively associated with the pair of drive rollers and are provided upon the outfeed side of the pair of drive rollers. Both the infeed and outfeed target rollers have sensor targets mounted thereon, and first and second proximity sensors are respectively disposed adjacent to the target rollers so as to in fact detect the presence of the sensor targets as the target rollers rotate at speeds proportional to the film speed. The film speed at the first or infeed target roller is different from the film speed at the second or outfeed target roller, and this difference in speeds comprises the amount of pre-stretch imparted to the film. The proximity sensors will generate pulse signals each time it detects one of the sensor targets each time, for example, the particular target roller completes a revolution, and these pulse signals will be transmitted to a first programmable logic controller (PLC), located upon the wrapping or packaging film dispensing carriage assembly, such that the first programmable logic controller (PLC) can then calculate the amount of pre-stretch actually being imparted to the wrapping or packaging film, as well as the amount of wrapping or packaging film actually being used for each wrapped load, or still further, for example, how many loads can in fact be wrapped or packaged using a single roll of film. All of the aforenoted data signals from the target roller proximity sensors, indicative of the film speeds and the amount of film usage, are, in turn, transmitted from the first programmable logic controller (PLC), located upon the wrapping or packaging film dispensing carriage assembly, to a second programmable logic controller (PLC), which is located within a remotely-located operator console, by means of first and second wireless transmission modules or transceivers. Accordingly, the operator can monitor such data and make any changes to the apparatus or system components as may be deemed necessary. 
         [0008]    A tension roller, which has incorporated therein a suitable strain gauge or load cell, is operatively associated with the pair of drive rollers so as to measure the tension being imparted to the wrapping or packaging film. The strain gauge or load cell will transmit appropriate sensed signals, indicative of the tension levels being imparted to the wrapping or packaging film, directly to a second programmable logic controller (PLC), located upon the remotely-located operator console or the like, such that the second programmable logic controller (PLC) can in fact calculate or determine the actual tension being imparted to the wrapping or packaging film. Still further, the overall film dispensing and wrapping system or apparatus of the present invention is also provided with several additional operational and safety features. For example, a photoeye is incorporated within the framework of the film dispensing and wrapping system or apparatus so as to monitor the amount of film remaining upon the roll of film mounted upon the film roll mounting spindle or mandrel. The photoeye is radially offset a predetermined amount with respect to, for example, an external peripheral portion of the mandrel or spindle, such that when the film, disposed upon the film roll, is depleted to such an extent that the diametrical extent of the film disposed upon the film roll is no longer captured by means of the photoeye, the photoeye will generate a signal indicating a low film level. This signal is also transmitted directly to the second programmable logic controller (PLC) whereby an operator, disposed at the operator console, can initiate the necessary operations to replace the depleted roll of wrapping or packaging film with a new or fresh roll of wrapping or packaging film. 
         [0009]    Continuing still further, the spindle or mandrel, upon which the roll of wrapping or packaging film is mounted, is pivotally movable from its normal, vertically upstanding operative position to a tilted or inclined LOAD/UNLOAD position at which the mandrel or spindle is disposed so as to facilitate the unloading of a depleted roll of film from the spindle or mandrel, and the mounting of a new or fresh roll of film onto the mandrel or spindle. Alternatively, after, for example, a new or fresh roll of film has been mounted upon the mandrel or spindle, the mandrel or spindle is pivotally moved back to its normal, vertically upstanding operative position such that the apparatus or system can now be employed to wrap or package a load within the wrapping or packaging film. The mandrel or spindle is also mounted upon a pivotal framework which includes a finger, and the finger operatively cooperates with a limit switch mounted upon the framework of the wrapping or packaging film dispensing carriage assembly so as to generate a signal when the mandrel or spindle framework has in fact been moved back to its normal, vertically upstanding operative position. This signal is also transmitted directly to the second programmable logic controller (PLC) located upon the operator console. Accordingly, if such a signal is not generated by the limit switch, indicating that the mandrel or spindle has not in fact been completely moved back to its normal, vertically upstanding operative position, the second programmable logic controller (PLC) will not initiate operation of the film dispensing and wrapping system or apparatus. 
         [0010]    Still yet further, it is also noted that another safety feature incorporated within the new and improved film dispensing and wrapping system or apparatus of the present invention resides in the provision of a third proximity sensor in conjunction with the door that is normally disposed at its CLOSED position with respect to the first and second drive rollers in order to protect operator personnel from any injuries involving the first and second drive rollers. More particularly, the door normally covering the first and second drive rollers is provided with a locking mechanism which includes, for example, a dead-bolt type locking member. Accordingly, when the locking mechanism is moved to its LOCKED position at which, for example, the dead-bolt locking member is moved to its EXTENDED position, this EXTENDED position of the dead-bolt locking member will be detected by means of this third proximity sensor. The third proximity sensor will generate a signal and transmit the same to the first programmable logic controller (PLC) which will permit operation of the film dispensing and wrapping system or apparatus to be initiated. If the first programmable logic controller (PLC) does not receive such a signal from the third proximity sensor, operation of the film dispensing and wrapping system or apparatus will be prevented. 
         [0011]    Lastly, at least one human-machine-interface (HMI) is provided upon the remotely-located operator console. The human-machine interface (HMI) may comprise various different formats or structures, such as, for example, a keyboard, a keypad, numerous USB ports, a screen monitor, or the like, by means of which operator personnel can effectively interface with, for example, the second programmable logic controller (PLC), and therefore, through means of the first and second wireless transmission modules or transceivers, with the first programmable logic controller (PLC) so as to in fact control the various power structures of the wrapping or packaging film dispensing carriage assembly. It is also to be noted that as a result of the provision of the human-machine-interface (HMI), which may, as noted, comprise, for example, one or more USB ports, operator personnel can effectively plug in a telephone, laptop computer, notebook, notepad, or the like, whereby all of the data stored, for example, within the second programmable logic controller (PLC), can be downloaded and transmitted to remote data storage servers or the like for usage at a later time. Control commands from the operator&#39;s laptop computer, notebook, notepad, or the like, can likewise be inputted back into the second programmable logic controller (PLC) for transmission back to the first programmable logic controller (PLC) so as to, for example, alter the various power drive signals for the various power-driven structures of the wrapping or packaging film dispensing carriage assembly so as to in fact achieve optimal output performance levels. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    Various other features and attendant advantages of the present invention will be more fully appreciated from the following detailed description when considered in connection with the accompanying drawings in which like reference characters designate like or corresponding parts throughout the several views, and wherein: 
           [0013]      FIG. 1  is a perspective view of a first conventional, PRIOR ART turntable type film wrapping or packaging machine; 
           [0014]      FIG. 2  is a perspective view of a second conventional, PRIOR ART rotary arm type film wrapping or packaging machine; 
           [0015]      FIG. 3  is a perspective view of a third conventional, PRIOR ART rotary ring type film wrapping or packaging machine; 
           [0016]      FIG. 4  is a perspective view of a wrapping or packaging film dispensing carriage assembly, as observed from the side of the wrapping or packaging film dispensing carriage assembly which faces the palletized load, as constructed in accordance with the principles and teachings of the present invention; 
           [0017]      FIG. 5  is a perspective view of the wrapping or packaging film dispensing carriage assembly as disclosed in  FIG. 4  and as observed from the side of the wrapping or packaging film dispensing carriage assembly which faces away from the palletized load; and 
           [0018]      FIG. 6  is a schematic perspective view of the wrapping or packaging film dispensing carriage assembly as disclosed in  FIG. 4  wherein the wrapping or packaging film dispensing carriage assembly is effectively disclosed as being relatively movable around a palletized load disposed at a package wrapping station, and wherein further, the wrapping or packaging film dispensing carriage assembly is disposed in communication with, for example, a programmable logic controller (PLC) disposed within a control cabinet. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0019]    Referring now to the drawings, and more particularly to  FIGS. 4 and 5  thereof, a wrapping or packaging film dispensing carriage assembly, which has been developed in accordance with the principles and teachings of the present invention and which may be used as a wrapping or packaging film dispensing carriage assembly upon any one of the film wrapping or packaging machines, systems, or apparatus as disclosed within  FIG. 1-3 , is illustrated and is generally indicated by the reference character  400 . The wrapping or packaging film dispensing carriage assembly  400  is adapted to be angularly moved in a rotating fashion relative or with respect to, for example, a palletized load  401  disposed at a wrapping or packaging station as schematically illustrated within  FIG. 6 . More particularly, it is seen, for example, that the wrapping or packaging film dispensing carriage assembly  400  is seen to comprise an upstanding spindle or mandrel  402  upon which a roll of wrapping or packaging film, illustrated at  403  within  FIG. 6 , is adapted to be mounted, and that, for example, first and second pre-stretch drive rollers  404 , 406 , and a suitable tension roller  408 , which contains a strain gauge or load cell, not shown, are adapted to be mounted upon the wrapping or packaging film dispensing carriage assembly  400 . More particularly, still further, in order to drive the first and second drive rollers  404 , 406 , it is seen that a drive motor  410  is mounted upon the wrapping or packaging film dispensing carriage assembly  400  at a position remote from the film roll mounting mandrel or spindle  402 , and that a first drive pulley  412  is operatively connected to the output drive shaft of the drive motor  410 . A first driven pulley  414  is disposed atop, and is operatively connected to, the upper end portion of the roller shaft upon which the first pie-stretch drive roller  404  is mounted, and it is seen that the first drive pulley  412  and the first driven pulley  414  are drivingly interconnected by means of a first drive belt  416 . A second driven pulley  418  is coaxially mounted atop the first driven pulley  414 , while a third driven pulley  420  is disposed atop, and is operatively connected to, the upper end portion of the roller shaft upon which the second pre-stretch drive roller  406  is mounted. A second drive belt  422  operatively interconnects the second and third driven pulleys  418 , 420 , and it is of course to be appreciated that the relative rotary speeds defined, or existing, between the first and second pre-stretch rollers  404 , 406  will in fact determine the amount of pre-stretch imparted to the wrapping or packaging film. Accordingly, it can be appreciated still further that the amount or percentage of pre-stretch imparted to the wrapping or packaging film may be predeterminedly defined or changed by predeterminedly matching particularly sized drive and driven pulleys  414 , 418 , 420  so as to in fact achieve predetermined rotary speed ratios between the first and second drive rollers  404 , 406 , wherein such differential speed ratios between the first and second drive rollers  404 ,  406  define or determine the aforenoted amount of pre-stretch imparted to the wrapping or packaging film. 
         [0020]    Continuing still further, and as can best be seen from  FIG. 5 , an infeed idler pinch roller  424  is rotatably mounted upon the wrapping or packaging film dispensing carriage assembly  400  such that oppositely disposed upper and lower end portions of the infeed idler pinch roller  424  extend between upper and lower members  426 , 428  of the wrapping or packaging film dispensing carriage assembly framework  430 , while an infeed idler target roller  432  is rotatably mounted in a similar manner upon the wrapping or packaging film dispensing carriage assembly  400  such that oppositely disposed upper and lower end portions of the infeed idler target roller  432  extend between the upper and lower members  426 , 428  of the wrapping or packaging film dispensing carriage assembly framework  430 . It will thus be appreciated that the infeed idler pinch roller  424  and the infeed idler target roller  432  are both located upstream of the first and second drive rollers  404 , 406  as considered in the direction of the feeding or the dispensing of the wrapping or packaging film from the roll of wrapping or packaging film disposed upon the upstanding spindle or mandrel  402 . The upper end portion of the infeed idler target roller  432  is provided with a sensor target  434 , which may simply be the head portion of a fastener screw threadedly engaged within the external peripheral wall portion of the infeed idler target roller  432 , and a first proximity sensor  436  is mounted upon a wall member  437  of the wrapping or packaging film dispensing carriage assembly framework  430  so as to be capable of detecting or sensing the presence of the infeed idler target roller sensor target  434  each time the infeed idler target roller  432  completes one revolution. 
         [0021]    In a similar manner, as can best be seen from  FIG. 4 , an outfeed idler pinch roller  438  is also rotatably mounted upon the wrapping or packaging film dispensing carriage assembly  400  such that oppositely disposed upper and lower end portions of the outfeed idler pinch roller  438  also extend between the upper and lower members  426 , 428  of the wrapping or packaging film dispensing carriage assembly framework  430 , while an outfeed idler target roller  440  is rotatably mounted in a similar manner upon the wrapping or packaging film dispensing carriage assembly  400  such that oppositely disposed upper and lower end portions of the outfeed idler target roller  440  likewise extend between the upper and lower wall members  426 , 428  of the wrapping or packaging film dispensing carriage assembly framework  430 . In a manner similar to that of the infeed idler pinch and target rollers  424 , 432 , it is seen that the outfeed idler pinch roller  438  and the outfeed idler target roller  440  are both located downstream of the first and second drive rollers  404 ,  406  as considered in the direction of the feeding or the dispensing of the wrapping or packaging film from the roll of wrapping or packaging film disposed upon the upstanding mandrel or spindle  402 . 
         [0022]    The upper end portion of the outfeed idler target roller  440  is also provided with a sensor target  442 , which may likewise be, similar to sensor target  434 , the head portion of a fastener screw threadedly engaged within the external peripheral wall portion of the outfeed idler target roller  440 , and a second proximity sensor  444  is mounted upon another wall member of the wrapping or packaging film dispensing carriage assembly framework  430  so as to be capable of detecting or sensing the presence of the outfeed idler target roller sensor target  442  each time the outfeed idler target roller  440  completes one revolution. It can thus be appreciated that the film path of the wrapping or packaging film, disposed upon and dispensed from the roll of wrapping or packaging film rotatably mounted upon the upstanding spindle  402 , extends from the roll of wrapping or packaging film, passes between the aforenoted first pinch roller  422  and the first target roller  432 , passes between or around the first and second drive rollers  404 ,  406 , passes around and across the external surface portion of the tension roller  408 , and between the second pinch roller  438  and the second target roller  440  so as to be conducted toward the palletized load to be wrapped or packaged within the wrapping or packaging film. 
         [0023]    Reverting back to the provision and disposition of the first and second target rollers  432 , 440  upon the wrapping or packaging film dispensing carriage assembly framework  430 , the provision and disposition of the sensor targets  434 , 442  upon the first and second target rollers  434 , 440 , and the provision and disposition of the first and second proximity sensors  436 , 444  upon the wrapping or packaging film dispensing carriage assembly framework  430 , it is to be noted that each time the first and second proximity sensors  436 , 444  detect the presence of the target roller sensor targets  434 ,  442 , indicating the rotary speeds of the target rollers  432 ,  440 , and therefore the linear speeds of the film at the target roller locations, the first and second proximity sensors  436 , 444  will generate pulses which are transmitted to a first programmable logic controller (PLC)  446  mounted upon the wrapping or packaging film dispensing carriage assembly  400  as can best be seen in  FIG. 5 . It is to be appreciated that the rotary speeds of the first and second target rollers  432 ,  440 , which are respectively indicative of the linear speeds of the film at the target roller locations, will be different, and that this difference in film speeds defines the amount of pre-stretch being imparted to the film as the same passes through or between the drive rollers  404 , 406 . Signals from the tension roller  408 , and more particularly, from the strain gauge or load cell incorporated therein, are also transmitted to the first programmable logic controller (PLC)  446 . 
         [0024]    The first programmable logic controller (PLC)  446  is operatively connected to a first wireless transmission module or transceiver  448 , which is located adjacent to the first programmable logic controller (PLC)  446  upon the wrapping or packaging film dispensing carriage assembly  400 , and it is to be appreciated that the first programmable logic controller (PLC)  446  is provided for calculating the pre-stretch level of the wrapping or packaging film, as well as the amount of the wrapping or packaging film usage, both of which are functions of the signals derived or received from the proximity sensors  436 , 444 . In turn, such data and calculations relating, for example, to the pre-stretch of the wrapping or packaging film, or to the amount of film used for a particular wrapping or packaging operation, are transmitted by means of the first wireless transmission module or transceiver  448  to a second wireless transmission module or transceiver  450  which may be located, for example, upon a main operator console or the like  452  as illustrated within  FIG. 6 . The main operator console or the like  452  may contain a second programmable logic controller (PLC)  454  within which all of the aforenoted data and calculations can be stored. It is to be noted further that the main operator console or the like  452  may also be provided with one or more types of suitable human machine interfaces (HMI)  456 , such as, for example, a keyboard, a keypad, numerous USB ports, a screen monitor, or the like. 
         [0025]    In this manner, the various aforenoted data and calculations may be displayed to operator personnel for monitoring purposes, as well as for modification purposes in connection with operational parameters in order to achieve optimal performance of the wrapping or packaging system. As was noted hereinbefore, the human-machine-interface (HMI)  456 , may comprise, for example, one or more USB ports such that operator personnel can effectively plug in a telephone, laptop computer, notebook, notepad, or the like, whereby all of the data stored, for example, within the second programmable logic controller (PLC)  454 , can be downloaded and transmitted to remote data storage servers or the like for usage at a later time. Control commands from the operator&#39;s laptop computer, notebook, notepad, or the like, can likewise be inputted back into the second programmable logic controller (PLC)  454  for transmission back to the first programmable logic controller (PLC)  446  so as to, for example, alter the various power drive signals for the various power-driven structures of the wrapping or packaging film dispensing carriage assembly  400  so as to in fact achieve optimal output performance levels. For example, predetermined tension levels to be imparted to the wrapping/packaging film can be pre-set by operator personnel entering such tension level data into the operator console  452  for control of the drive motor  410  through means of the first and second programmable logic controllers (PLCs)  446 , 454 . Accordingly, if the tension impressed upon the film is in fact too low or too high, as transmitted, for example, by means of the strain gauge operatively associated with the tension roller  408  to the second programmable logic controller (PLC)  454 , the control of the drive motor  410  can be altered by means of suitable control signals sent to the drive motor  410  by operator personnel located at the operator console  452  and transmitted from the human machine interface (HMI)  456  and through the second programmable logic controller (PLC)  454 , the second wireless transmission module or transceiver  450 , the first wireless transmission module or transceiver  448 , and the first programmable logic controller (PLC)  446 . 
         [0026]    In a similar manner, operator personnel can likewise monitor the amount of pre-stretch being imparted to the wrapping or packaging film, or the amount of film being used per load being wrapped or packaged. Accordingly, operator personnel can, for example, order or initiate necessary changes to be made to the use of particular ones of the first and second drive rollers  404 , 406 , or to their operatively associated pulley drives  414 , 418 , 420 , such that the relative speeds of the first and second drive rollers  404 , 406  is altered in accordance with optimal or desired pre-stretch parameters. Similar changes or alterations can be made if the amount of film actually being used deviates from predetermined or prescribed target values. Alternatively, based upon the various aforenoted detected data, information, values, percentages, ratios, or the like, the operator personnel may simply determine that suitable maintenance is required for the apparatus. For example, it may simply be that the wrapping or packaging film was incorrectly threaded or routed through the roller arrays upon the wrapping or packaging film dispensing carriage assembly  400 . It is lastly to be appreciated, in connection with the aforenoted components comprising the film wrapping or packaging system, that the first and second wireless transmission modules  448 , 450  are preferably transceivers or the like in order to in fact permit two-way communication between the first and second programmable logic controllers (PLCs)  446 , 454 . Still yet further, as has been noted, the provision of the multiple USB ports permits other auxiliary devices, such as, for example, laptop, notebook, or similar portable computers, printers, cell phones, routers, internet connect-ors, and the like, to operatively interface with the main operator console  452  whereby operator personnel can control the operative elements of the film wrapping or packaging system by means of such auxiliary devices. 
         [0027]    Continuing still further, the system or apparatus of the present invention, comprising, for example, the wrapping or packaging film dispensing carriage assembly  400 , is also provided with various other safety or operational elements or features. For example, the wrapping or packaging film dispensing carriage assembly  400  is provided with means for indicating to operator personnel that the amount of film remaining upon the roll of film, and to be dispensed in connection with a film wrapping or packaging operation, is running low and is about to run out. More particularly, as can best be appreciated from  FIG. 5 , the wrapping or packaging film dispensing carriage assembly  400  is provided with a photodetector or photoeye  458  which is mounted within the upper wall member  426  of the wrapping or packaging film dispensing carriage assembly  400 . The photoeye  458  is located at a radial position that is slightly offset with respect to the cylindrical axis of the film roll mounting mandrel or spindle  402 , upon which the existing roll of wrapping or packaging film is located, such that the line of sight of the photoeye is effectively axially aligned with an external peripheral surface portion of the film roll mounting spindle  402 . In this manner, as the wrapping or packaging film, comprising the film roll disposed upon the film roll mounting spindle  402 , is progressively depleted, there will come a time when the photoeye  458  will no longer detect the presence of film, coiled upon the film roll core of the roll of film, whereupon an alarm or other signal will be generated and transmitted directly to the second programmable logic controller (PLC)  454  whereby the second programmable logic controller (PLC)  454  will cause an alarm or alert message for operator personnel to hear, or to see or read upon the human machine interface (HMI)  456 . The operator personnel can then, of course, shut down the apparatus or system from the operator console  452  so as to in fact permit other operator personnel to remove the depleted, or soon to be depleted, roll of wrapping or packaging film from the film roll mounting spindle  402  and to replace the same with a new or fresh roll of wrapping or packaging film such that a wrapping or packaging operation is not to be performed without an adequate supply of wrapping or packaging film present upon the wrapping or packaging film dispensing carriage assembly  400 . 
         [0028]    In connection with the aforenoted replacement of the roll of wrapping or packaging film, it is further noted that the film roll mounting spindle or mandrel  402  is normally disposed in a vertically upstanding operative position as illustrated within  FIGS. 4 and 5 . However, the film roll mounting spindle  402  is in fact capable of being tilted outwardly from, or with respect to, its normally disposed vertically upstanding operative position, such as, for example, through an angular movement of approximately 45°, so as to in fact facilitate the removal of the depleted roll of wrapping or packaging film from the film roll mounting spindle  402  and the mounting of a new or fresh roll of wrapping or packaging film onto the film roll mounting spindle  402 . 
         [0029]    As a safety feature incorporated into the wrapping or packaging film dispensing carriage assembly  400 , a limit switch is disposed internally within a bracket housing  460  which is mounted upon the side wall member  437  of that portion of the framework  430  of the wrapping or packaging film dispensing carriage assembly  400  which effectively houses the film roll mounting mandrel or spindle  402  and the roll of wrapping or packaging film mounted thereon. In addition, as can best be appreciated from  FIG. 4 , the upstanding film roll mounting spindle  402  is fixedly secured upon a substantially U-shaped mounting bracket which comprises a bottom cross-piece member  464  and a pair of oppositely disposed upstanding side members  466 , 468 . The upper end portions of the side members  466 , 468  are respectively pivotally secured to the side wall member  437  and an opposite side wall member  470  of the carriage assembly framework  430 , as at  472 , 474 , so as to in fact permit the upper free end portion of the upstanding film roll mounting spindle  402  to tilt outwardly and downwardly, in an arcuate manner, toward the right as viewed in  FIG. 5 , while, conversely, the bottom end portion of the upstanding film roll mounting spindle  402  will tilt upwardly and toward the right as viewed within  FIG. 4 . 
         [0030]    As can also best be seen in  FIG. 4 , the lower corner portions of the substantially U-shaped mounting bracket, as defined between the bottom cross-piece member  464  and the pair of oppositely disposed upstanding side members  466 ,  468 , are provided with corner brackets  476 , 478  which effectively prevent the upstanding film roll mounting spindle  402 , and its substantially U-shaped mounting bracket, from overshooting its proper disposition when being rotated back from its outward pivotal or inclined film loading/unloading position to its normal operative position as a result of the corner brackets  476 , 478  engaging the lower end portions of the side wall members  437 , 470  of the framework  430  of the wrapping or packaging film dispensing carriage assembly  400 . As can best be additionally appreciated from  FIG. 5 , the upstanding side member  466  of the U-shaped bracket is also provided with a finger  480  which engages and closes the limit switch, disposed internally within the bracket housing  460 , when the upstanding film roll mounting spindle  402  has in fact been moved back to its normal upstanding operative position. 
         [0031]    Accordingly, it can be readily appreciated that the limit switch, disposed within the bracket housing  460 , is thus provided so as to effectively detect the fact that the film roll mounting spindle  402 , and its substantially U-shaped mounting bracket  464 , 466 , 468 , has in fact been moved back to its normally vertically upstanding operative position. If the limit switch  460  does not detect this normally vertically upstanding disposition of the film roll mounting spindle  402 , it will not generate an appropriate signal to the second programmable logic controller  454  whereby the second programmable logic controller  454  will effectively prevent the apparatus or system from operating. 
         [0032]    An additional safety feature incorporated into the wrapping or packaging film dispensing carriage assembly  400  comprises the use of a third proximity sensor  482  which is positioned, for example, upon that portion of the upper wall member  426  of the wrapping or packaging film dispensing carriage assembly  400  which effectively forms a ceiling for the section of the wrapping or packaging film dispensing carriage assembly  400  which houses the first and second drive rollers  404 , 406 . This housing section of the wrapping or packaging film dispensing carriage assembly  400  is normally covered by means of a door, not shown, which is hingedly mounted upon the wrapping or packaging film dispensing carriage assembly  400  between OPEN and CLOSED positions. The door, not shown, is normally disposed at its CLOSED position during operational cycles so as to in cover or encase the first and second drive rollers  404 , 406  and thereby prevent operator personnel from being subjected to unsafe conditions by otherwise accidentally encountering the first and second drive rollers  404 ,  406 . The door, not shown, may, however, be moved to its OPEN position during, for example, initial start-up procedures wherein the manual threading of the wrapping or packaging film along its sinusoidal flow path between the first and second drive rollers  404 , 406  needs to be carried out. The door, not shown, may have, for example, a locking mechanism disposed thereon which may, for example, be similar to a dead-bolt locking assembly, wherein when the door, not shown, is locked, the dead-bolt is moved to its locked position that can effectively be detected by means of the proximity sensor  482 . Accordingly, if the proximity sensor  482  does not detect the fact that the door, not shown, normally covering and enclosing the first and second drive rollers  404 , 406 , has in fact been moved to, and locked at, its CLOSED position by means of the dead-bolt member being disposed at its EXTENDED and LOCKED position, such proximity sensor  482  will emit a signal to the first programmable logic controller (PLC)  446  so as to likewise effectively prevent the film wrapping or packaging apparatus or system from initiating a film wrapping or packing operational cycle. 
         [0033]    Thus, it may be seen that in accordance with the principles and teachings of the present invention, there has been disclosed a new and improved film dispensing and wrapping system or apparatus wherein a wrapping or packaging film dispensing carriage assembly has been provided with a pair of drive rollers which are driven at different speeds by means of a drive motor and a belt-and-pulley drive system so as to impart a predetermined amount of pre-stretch to the wrapping or packaging film. An infeed target roller and an infeed pinch roller are operatively associated with the pair of drive rollers and are provided upon the infeed side of the pair of drive rollers, while an outfeed target roller and an outfeed pinch roller are also operatively associated with the pair of drive rollers and are provided upon the outfeed side of the pair of drive rollers. Both the infeed and outfeed target rollers have sensor targets mounted thereon, and first and second proximity sensors are respectively disposed adjacent to the target rollers so as to in fact detect the presence of the sensor targets as the target rollers rotate at speeds proportional to the film speed. The film speed at the first or infeed target roller is different from the film speed at the second or outfeed target roller, and this difference in speeds comprises the amount of pre-stretch imparted to the film. The proximity sensors will generate pulse signals each time it detects one of the sensor targets each time, for example, the particular target roller completes a revolution, and these pulse signals will be transmitted to a first programmable logic controller (PLC), located upon the wrapping or packaging film dispensing carriage assembly, such that the first programmable logic controller (PLC) can then calculate the amount of pre-stretch actually being imparted to the wrapping or packaging film, as well as the amount of wrapping or packaging film actually being used for each wrapped load, or still further, for example, how many loads can in fact be wrapped or packaged using a single roll of film. 
         [0034]    A tension roller, which has incorporated therein a suitable strain gauge or load cell, has been operatively associated with the pair of drive rollers so as to measure the tension being imparted to the wrapping or packaging film. The strain gauge or load cell will also transmit signals, indicative of the sensed tension values, to a second programmable logic controller (PLC), which is located within a remotely-located operator console, by means of first and second wireless transmission modules or transceivers such that the second programmable logic controller (PLC) can in fact calculate or determine the actual tension being imparted to the wrapping or packaging film. All of the aforenoted data signals from the target roller proximity sensors, indicative of the film speeds and the amount of film usage, and from the tension roller, indicative of the tension levels being imparted to the wrapping or packaging film, can be accessed by operator personnel by means of a human-machine interface also located upon the remotely-located operator console, and accordingly, the operator can monitor such data and make any changes to the apparatus or system components as may be deemed necessary. 
         [0035]    Still yet further, the new and improved film dispensing and wrapping system or apparatus of the present invention has also been provided with several additional operational and safety features. For example, a photoeye is incorporated within the framework of the film dispensing and wrapping system or apparatus so as to monitor the amount of film remaining upon the roll of film mounted upon the film roll mounting spindle or mandrel. The photoeye is radially offset a predetermined amount with respect to, for example, an external peripheral portion of the mandrel or spindle, such that when the film, disposed upon the film roll, is depleted to such an extent that the diametrical extent of the film disposed upon the film roll is no longer captured by means of the photoeye, the photoeye will generate a signal indicating a low film level. This signal is transmitted directly to the second programmable logic controller (PLC), whereby, again, an operator, disposed at the operator console, can initiate the necessary operations to replace the depleted roll of wrapping or packaging film with a new or fresh roll of wrapping or packaging film. Continuing still further, the spindle or mandrel, upon which the roll of wrapping or packaging film is mounted, is pivotally movable from its normal, vertically upstanding operative position to an inclined or tilted LOAD-UNLOAD position at which the mandrel or spindle is disposed so as to facilitate the unloading of a depleted roll of film from the spindle or mandrel, and the mounting of a new or fresh roll of film onto the mandrel or spindle. Accordingly, after, for example, a new or fresh roll of film has been mounted upon the mandrel or spindle, the mandrel or spindle is pivotally moved back to its normal, vertically upstanding operative position such that the apparatus or system can now be employed to wrap or package a load within the wrapping or packaging film. The mandrel or spindle is also mounted upon a pivotal framework which includes a finger, and the finger operatively cooperates with a limit switch mounted upon the framework of the wrapping or packaging film dispensing carriage assembly so as to generate a signal when the mandrel or spindle framework has in fact been moved back to its normal, vertically upstanding operative position. This signal is transmitted directly to the second programmable logic controller (PLC). Accordingly, if such a signal is not generated by the limit switch, indicating that the mandrel or spindle has not in fact been completely moved back to its normal, vertically upstanding operative position, the second programmable logic controller (PLC) will not initiate operation of the film dispensing and wrapping system or apparatus. 
         [0036]    It is lastly noted that another safety feature incorporated within the new and improved film dispensing and wrapping system or apparatus of the present invention resides in the provision of a third proximity sensor in conjunction with the door that is normally disposed at its CLOSED position with respect to the first and second drive rollers in order to protect operations personnel from any injuries involving the first and second drive rollers. More particularly, the door normally covering the first and second drive rollers is provided with a locking mechanism which includes, for example, a dead-bolt type locking member. Accordingly, when the locking mechanism is moved to its LOCKED position at which, for example, the dead-bolt locking member is moved to its EXTENDED position, this EXTENDED position of the dead-bolt locking member will be detected by means of this third proximity sensor. The third proximity sensor will generate a signal and transmit the same to the first programmable logic controller (PLC) which will permit operation of the film dispensing and wrapping system or apparatus to be initiated. If the first programmable logic controller (PLC) does not receive such a signal from the third proximity sensor, operation of the film dispensing and wrapping system or apparatus will be prevented. 
         [0037]    Obviously, many variations and modifications of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described herein.