Patent Publication Number: US-2020282634-A1

Title: Automated wrapping system

Description:
RELATED APPLICATION 
     This application claims priority to and all advantages of U.S. Provisional Patent Application No. 62/569,663, which was filed on Oct. 9, 2017; and U.S. Provisional Patent Application No. 62/683,127, which was filed on Jun. 11, 2008, the disclosures of which are specifically incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention generally relates to wrapping systems for wrapping materials onto a substrate, and more particularly to automated wrapping systems for wrapping materials onto a substrate. 
     2. Description of Related Art 
     Currently parts in various industries such as automotive, heavy truck, aerospace, motorcycle, furniture, and so forth have vinyl, leather, cloth, polyolefin or other fabric like materials wrapped over them to cover up the part structure underneath. This wrapping thus provides a number of benefits by making the part softer to the touch, reducing the chance of exposure to sharp edges, covering subtle flaws and inconsistencies within/on the substrate, as well as increasing the aesthetic appearance of the product. This upturn of safety, comfort, and visual appearance magnifies the product&#39;s value, quality, and overall influence on the customer&#39;s satisfaction. For instance, an automobile typically provides a center console lid with leather or vinyl wrapping over the plastic part substrate structure, this is where a human&#39;s arm rests when driving. Additional vehicular parts and products that use an equivalent or similar wrapping would include pillar covers, instrument panels, seats, steering wheels, door panels, floor mats, and so on. 
     The wrapped material is commonly attached/fastened to these part substrate structures with staples or glue or hog-rings etc. A center console lid, for example, is stapled in the areas accessible for a staple gun to properly install the staple. In this instance staples are paramount for securing the vinyl or leather to the substrate structure. 
     For thousands of years humans have wrapped leather/vinyl like material (i.e. animal hide) and it is understandable why this had to be done by hand in the past. However, despite modern technology and advancements in manufacturing processes, this wrapping and fastening process is still done by hand. This procedure is a very labor intensive and expensive. Moreover, it is a time-consuming process that also tends to lack consistency due to the following negative issues associated with manual hand wrapping and fastening. 
     The subject invention provides an automated wrapping system to address these issues. 
     SUMMARY OF THE INVENTION AND ADVANTAGES 
     The subject invention relates to an automated wrapping system for wrapping/trimming a substrate with a material, with the substrate having an outer portion and an inner portion and an edge connecting the inner portion to the outer portion. The automated wrapping system comprises a support and a nest mounted to the support, with the nest configured to position the material between the outer portion of the substrate and the nest. The material includes a free end portion not positioned between the nest and the outer portion of the substrate. The automated wrapping system also comprises a material folding assembly positioned adjacent to the nest and includes a sub-assembly configured for movement between a rest position and an actuated position. The automated wrapping system also comprises an actuator connected to the sub-assembly and configured to move the sub-assembly to the actuated position for engaging and folding the free end portion of the material over the edge of the substrate and onto a part of the inner portion of the substrate. 
     The subject invention provides the industry, as well as individuals, throughout the world a safer, more accurate, simpler, worker health conscious, efficient, faster, more economic and financially advantageous method to wrap, align, stretch and fasten material over substrates (i.e., part structures). 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings. 
         FIG. 1  is a perspective view of an automated wrapping system in accordance with one embodiment with a material folding assembly having a sub-assembly in a rest position. 
         FIG. 2  is a perspective view of the material folding assembly of  FIG. 1  having the sub-assembly in the rest position. 
         FIG. 2A  is a close-up view of a portion of  FIG. 2  in circle  2 A. 
         FIG. 3  is a perspective view of the material folding assembly of  FIG. 1  having the sub-assembly in an actuated position. 
         FIG. 4  is a perspective view of  FIG. 1  with the sub-assembly in the actuated position. 
         FIG. 5  is a fragmented partially cross-sectional side view of the automated wrapping system of  FIG. 1  with the sub-assembly in the actuated position and a platen in a raised position. 
         FIG. 6  is a close-up view of a portion of  FIG. 5 . 
         FIG. 7  close-up view of a portion of  FIG. 5  further including a fastening mechanism of an interface between material folder, stapler head and material. 
         FIG. 8  is a perspective view of an alternative embodiment of the automated wrapping system with a material folding assembly having a sub-assembly in a rest position. 
         FIG. 9  is a front view of a material folding assembly of the alternative automated wrapping system of  FIG. 8  with the sub-assembly in the rest position. 
         FIG. 10  is a front view of a material folding assembly of the alternative automated wrapping system of  FIG. 8  with the sub-assembly in the actuated position. 
         FIG. 11  is a perspective view of an alternative embodiment of a material folding assembly having a sub-assembly in a rest position. 
         FIG. 12  is a perspective view of the material folding assembly of  FIG. 11  having the sub-assembly in the rest position and the biasing slide in a non-operational position. 
         FIG. 12A  is a perspective view of an automated wrapping system with the material folding assembly of  FIG. 11  having the sub-assembly in an actuated position and the biasing slide in the non-operational position. 
         FIG. 13  is a perspective view of an automated wrapping system with the material folding assembly of  FIG. 11  having the sub-assembly in an actuated position and the biasing slide in an operational or biasing position. 
         FIG. 14  is a perspective view of an alternative embodiment of a material folding assembly having a sub-assembly in a rest position. 
         FIG. 15  is a perspective view of the material folding assembly of  FIG. 15  having the sub-assembly in the actuated position. 
         FIG. 16  is a side perspective view of an alternative embodiment of the automated wrapping system with a material folding assembly having a sub-assembly in a rest position and a stretching device in a non-engaged position. 
         FIG. 17  is a perspective view of the material folding assembly of  FIG. 16  having the sub-assembly in the actuated position and a stretching device in the non-engaged position. 
         FIG. 18  is a perspective view of the material folding assembly of  FIG. 16  having the sub-assembly in an actuated position and the stretching device in an engaged position. 
         FIG. 19  is a close-up perspective view of the stretching device of  FIG. 18  in the activated position. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to the Figures, wherein like numerals indicate like parts throughout the several views, various embodiments of an automated wrapping system are shown in the attached Figures and description. As is clear from the Figures and description, the subject automated wrapping system virtually eliminates waste that is found from the trimming processes of the prior art. 
     The automated wrapping system  20  of each of the representative embodiments utilizes a substrate nest, or nest,  21  mounted on a support  22 , which is in turn supported by footings  23 . It is to be appreciated that the support  22  and footings  23  can be of any suitable design or configuration, and the nest  21  will be configured with a particular contour/features to match a component  24  to be trimmed. 
     The component, otherwise referred to as a part structure or substrate  24 , is to be wrapped (i.e., trimmed) with a material  55 , and the resultant trimmed substrate forms a desired part  100 . As used hereinafter, the terms “trimmed” and “wrapped” may be used interchangeably. Exemplary parts  100  that can be formed in accordance with the subject invention include, but are not limited, to vehicular parts such as center console lids, pillar covers, instrument panels, seats, steering wheels, door panels, floor mats, and so on. The substrate  24  and material  55  may be of any suitable type, design or configuration as known in the industry. For example, the substrate  24  may be a plastic, and the material  55  may be a leather or faux leather trim. 
     In addition, the automated wrapping system  20  of each of the representative embodiments utilizes a material folding assembly, shown at  25 , to couple the material  55  to the substrate  24 , and in particular to wrap the free end portion  56  of the material  55  onto an edge  24   a  and inner portion  24   b  of the substrate  24 . The material folding assembly  25  includes a sub-assembly, as described in the various embodiments, below that moves between a rest position and an actuated position (alternatively the material folding assembly  25  is described in certain instances of moving between the rest positon and actuated positon). When in the actuated position, as will be described in various embodiments below, the material folding assembly  25  engages and folds the free end portion  56  of the material  55  over the edge  24   a  of the substrate  24  and onto a part of the inner portion  24   b  of the substrate  24  while retaining the material against the edge  24   a  of the substrate  24 . In certain embodiments, the material folding assembly  25  retains the material against the edge of the substrate prior to the material folding system and sub-assembly being moved to the actuated position. The sub-assembly includes a number of operative components as described below, but can include more or less components without deviating from the overall scope of the invention. 
     As described herein, the material folding assembly  25 , including the moveable sub-assembly, can be configured in a variety of ways and function to trim, or wrap, or otherwise cover the substrate  24  with material  55 . 
     In one embodiment, as shown in  FIGS. 1-7 , the material folding assembly  25  is mounted on an assembly flange  33 , which is positioned adjacent to the nest  21 . In certain embodiments, the assembly flange  33  can be coupled to the support  22 , or mounted to the support  22 , or integrally formed with the support  22 . In this embodiment, the moveable sub-assembly is referred to by reference numeral  39 . 
     The material folding assembly  25  in this embodiment includes an end block  26  with an actuation rod  27  pivotally connected thereto. There is a fixed mount  28  bolted to a biasing slide  34 . A moveable mount  29  is mounted to the fixed mount  28  with a slide folder  30  moving along the moveable mount  29  during operation. 
     A material folder  31 , having a bottom edge  31   b,  is mounted to the slide folder  30 . A connector  32  is mounted to the material folder  31  with the actuation rod  27  interconnecting the connector  32  (and material folder  31 ) and the end block  26 . It should be appreciated that the specifics of the sliding structure of the sub-assembly  39  can be modified without deviating from the overall scope of the invention so long as the material folder is able to move from a rest position to an actuated position. 
     The biasing slide  34  is moveably mounted to a slide mount  35  and carries the material folder  31  is coupled to an actuator. A slide spring  36  provides a continuous biasing force to the biasing slide  34 . As best shown in  FIG. 5 , the biasing slide  34  includes a retainer section  44 . When in operation, as shown in  FIG. 1  (when the material folding assembly  25  is in the rest position) and  FIG. 5  (when the material folding assembly  25  is in the actuated position), the biasing slide  34  is moved to a biasing position such that that retainer section  44  engages the free end portion  56  of the material  55  extending outwardly from the nest  21  to hold this free end portion  56  of the material  55  in position against an edge  24   a  of the substrate  24 . Typically, the movement of the biasing slide  34  is via an actuator (such as through actuator  46 ), but also can be accomplished by moving the material folding assembly  25  in a wide variety of other ways. The retainer section  44  includes a contoured engagement surface  44   a  (see  FIG. 2A ) that directly engages the material  55  at the edge of the substrate  24 . The engagement surface can be in form of a groove, such as a continuous groove, or any other suitable configuration to grip against the material  55 . 
     The material folder  31  engages a free end portion  56  of the material  55  to fold the material  55  inward against a part of an inner portion  24   b  of the substrate  24  when the material folding assembly  25  and sub-assembly  39  are in the actuated position, and holds this free end portion  56  of the material  55  in position against the interior portion  24   b  of the substrate  24 . An interior surface of the material folder  31  could be scored or have some other rough surface to grip and pull or tension the free end  56  of the material  55 . The material  55  may then be secured to the interior portion  24   b  of the substrate  24 , such as by stapling or any other suitable means. The continuous biasing by the slide spring  36  when the biasing slide is in the operational, or biasing positon, automatically maintains the requisite pressure of the retainer section  44  against the material  55  at the edge  24   a  of the substrate  24 . 
     In certain embodiments, the nest  21  may include a plurality of holes  21   a,    21   b  to permit passage of a vacuum to hold the material  55  in position against a bottom of the nest  21 . The upper walls of the nest  21  are smaller than the perimeter walls of the substrate  24  to allow the edges  24   a  of the substrate  24  to project outward from the nest  21 , which allows proper operation of the system as described above. 
     An actuator  46  provide the actuation of the material folder  31  through the actuation rod  27  and connector  32 . In particular, the actuator  46  in the embodiment of  FIGS. 1-7  includes an air cylinder mount  37  that supports an air cylinder  38 . The air cylinder  38  includes a moveable cylinder rod  38   a.  The air cylinder  38  is connected to the end block  26  to provide the actuation of the material folder  31  through the actuation rod  27  and connector  32 . In particular, the cylinder rod  38   a  of the actuated actuator  46  is extended outwardly in a direction towards the nest  21  and applies force on the end block  26  to move the end block  26  longitudinally towards the material folder  31  from a first slid position (see  FIGS. 1-3 ) to a second slid position (see  FIGS. 4-5 ), with the first slid position corresponding to the rest position of the sub-assembly  39  and material folding assembly  25  and the second slid position corresponding to the actuated position of the sub-assembly  39  and material folding assembly  25 . The movement of the end block  26  towards the material folder  31  causes the upper end  27   a  of the actuation rod  27  to rotate about the upper pivoting point, corresponding to the pivotal coupling of the upper end  27   a  of the actuation rod  27  to the end block  26 . The lower end  27   b  of the actuation rod  27 , which is separately pivotally coupled to the connector  32 , applies a downward force on the connector  32  and material folder  31  to move the sub-assembly  39  and material folding assembly  25  (and in particular the material folder  31 ) to the actuated position (the movement is illustrated by the arrow  50  in  FIG. 3 ), in which the end  31   b  of the material folder  31  contacts the material  55  and folds the end of the material  55  over the substrate  24  (see  FIG. 5 ). During this movement, the slide folder  30  slides downward along the moveable mount  29  and aids in the stability of the movement of the material folder  31  to the engaged state. 
     It is to be appreciated, that any suitable automation technique or sub-system could be employed without deviation from the scope of the invention. For example, the actuator  46  in this embodiment is in the form of a hand actuating device  40  utilizing a handle  41  coupled to a linkage  42  (see the alternative embodiment in  FIGS. 11-13 ), which may replace the air cylinder mount  37  and air cylinder  38  for use as the actuator  46 , in which a user simply pivots or otherwise moves the handle  41 , thereby moving the linkage  42  longitudinally to contact the end block  26  in the manner described above. 
     Referring now to  FIG. 5 , a platen or pressure plate  45  may also be provided as a part of the automated wrapping system  20  to apply pressure against the interior portion  24   b  of the substrate  24 . As known to those skilled in the art, a thin layer of foam  82  (see  FIGS. 6 and 7 ) is typically disposed between the trim/material  55  and the substrate  24 . The platen  45  applies uniform pressure to the substrate  24  to compress the foam  82  between the trim/material  55  and the outer portion  24   c  of the substrate  24 . This in turn allows the material  55  to “stretch” or extend about the periphery of the outer portion  24   c  of the substrate  24 . The pressure by the platen  45  is preferably applied prior to the material folding assembly  25  engaging the free end portion  56  of the material  55  when the sub-assembly is moved to the actuated position. Meaning, the free end portions  56  of the trim/material  55  are free when the pressure is applied. After the pressure is applied, and while maintaining the pressure, the material folding assembly  25  comes into position to pull, stretch, or otherwise tension the free end portion  56  of the trim/material  55  and foam layer  82  and fold the material  55  about the edge  24   a  and inner portion  24   b  of the substrate  24 . As mentioned above, this is accomplished by the retainer section  44  and the material folder  31 . Once the free end portions  56  of the trim/material  55  are held in position against the inner portion  24   b  of the substrate  24  by the material folding assembly  25  as will be described in further detail below, the platen  45  is raised and the pressure is released, which then causes the foam to automatically tension the material  55  about the substrate  24 , and in particular against the outer portion  24   c  of the substrate  24 . As appreciated, the platen  45  operates in concert with the biasing slide  34  and the material folder  31  in this embodiment to properly position and tension the material  55  about the substrate  24 . Now that the platen  45  has been removed, there is sufficient room to allow a fastening mechanism to affix the free end portions  56  of the material  55  to the inner portion  24   b  of the substrate  24 . 
     Openings  21   b  (see  FIG. 1 ) may also be provided in the nest  21  to permit access by an alignment system  75 . In particular, the openings  21   b  allow an alignment system  75 , here a vision system  77  such as a laser system and/or a camera system  79  (such as a visible light camera system), to view the stitches along the trim/material  55  to ensure that the material  55  is properly aligned on the substrate  24 . If there is a misalignment, the pressure by the platen  45  and/or suction by the vacuum can be reduced to allow adjustment of the material  55  relative to the substrate  24 . The openings  21   b  may be the same as openings  21   a  in certain embodiments (and are labelled accordingly in the FIGS. Provided herein), or different from openings  21   a  in other embodiments. 
     As noted above, the automated wrapping system  20  also includes a fastening mechanism that is used to attach the material  55  to the substrate  24 . The fastening mechanism, such as a stapler  70  having a stapler head  71 , is shown in  FIG. 7 . An interface  72  of the stapler head  71  and the free end portion  56  of the material  55  is also shown in  FIG. 7  that provides the location for the affixing of the staples  81 . The bottom edge  31   b  of the material folder  31  provides a guide for ensuring consistent and accurate positioning of the interface  72  relative to the free end portion  56  of the material  55 . This precision further reduces the extra material needed to secure the material  55  to the substrate  24 . As appreciated, the free end portion  56  of the material  55  will be secured to the substrate  24  along the inner portion  24   b.  This can be accomplished by moving the fastening mechanism, such as the stapler  70 , or by rotating the substrate  24  about the inner portion  24   b  relative to the fastening mechanism. The rotation can be accomplished on a carousel (not shown) as known in the industry. It is to be appreciated that any suitable fastening mechanism could be employed. 
     In certain embodiments, a bevel  73  is added to the stapler head  71  that corresponds to a corresponding outer profile shape of the bottom edge  31   b  of the material folder  31 . Alternatively, a bevel (not shown) can be added to the bottom edge  31   b  of the material folder  31  to correspond to the outer profile shape of the stapler head  71 . In this way, the stapler  70  can be more precisely guided to a position adjacent to the free end portion  56  of the material  55  to apply the staples to fasten the free end portion  56  to the inner portion  24   b  of the substrate  24 . Accordingly, the variation of the location of the staples used to fasten the material  55  to the substrate  24  can be minimized on a part to part basis. 
     The general method of operation, in the embodiment of  FIGS. 1-7 , is as follows. The trim/material  55  is loaded into the nest  21 , preferably while a vacuum (not shown) is operational and inserted within the openings  21   a  or  21   b.  The stitching  83  on the material  55  is aligned, and the location of the stitches  83  of the material  55  is checked, and re-checked after any necessary adjustment. The vision system  77 , and/or camera system  79 , used as the alignment system  75  may provide a green light or some form of feedback indicating that the material  55  is properly aligned on the nest  21 . The substrate  24  is then loaded against the trim/material  55  such that the outer portion  24   b  is positioned adjacent to the trim/material  55 . The alignment of the stitching is re-checked. The vision system  77  and/or camera system  79 , used in the alignment system  75  may provide a green light or some form of feedback indicating that the material  55  remains properly aligned on the nest  21 . 
     The platen  45 , if utilized, is then lowered into position to apply the desired pressure to the substrate  24  and to compress the foam layer  82 . The biasing slide  34  is then moved to the operational, or biasing position, wherein the retainer section  44  holds the material  55  against the edge  24   a  of the substrate  24 . The material folding assembly  25  is then activated, wherein the actuator  46  moves the material folding assembly  25  and sub-assembly  39  from the rest position to the actuated position. The platen  45 , and the material folding system  25 , could be activated simultaneously, or in any suitable sequence. The material folder  31  is moved into the actuated position wherein it holds, folds, pulls and otherwise tensions and secures the trim/material  55  to the substrate  24 , and in particular folds the free end portion  56  of the material  55  over the edge  24   a  and onto a part of the inner portion  24   b  of the substrate  24 . The platen  45  is then preferably raised/retracted. The fastening mechanism, such as the stapler  70 , is moved into position, either manually or automated, to secure staples  81  (see  FIG. 1 ) into the free end portions  56  of the material  55  to the substrate  24 . After the staples  81  or other fasteners are inserted, the material folder  31  is retracted to the rest position and the retainer section  44  is withdrawn to a non-operational position (i.e., a non-biasing position). The finished part  100 , having the material  55  secured to the substrate  24  with the free end portions  56  adjacent to the inner portion  24   b  of the substrate  24 , can now be removed from the nest  21 . 
       FIGS. 8-10  illustrate an alternative embodiment to the embodiment provided in  FIGS. 1-7 , where the material folder  31  has a different configuration. This configuration allows for the same securing process to occur on non-linear shapes. Specifically, the modified sub-assembly  109  provided herein includes three material folders  131   a,    131   b,  and  131   c  that all actuate in concert with each other. Each material folder  131   a,    131   b,    131   c  has a respective folder slide  132   a,    132   b ,  132   c  that moves along a respective moveable mount  133   a,    133   b,    133   c.  The actuation rod  27  is now an l-shaped rod  27   d  and is connected to a journal  120 , which in turn leads to two additional actuation rods  27   b  and  27   c  which are connected to a respective one of the two additional material folders  131   b  and  131   c.  Again, it is to be appreciated that the sub-assembly  109  can be of any suitable configuration so long as the material  55  is properly held into position about an edge of the substrate. 
     In this embodiment, the actuation of the sub-assembly  109  from the rest position (see  FIG. 9 ) to the actuated position (see  FIG. 10 ) is accomplished wherein the air cylinder  38  is activated and the cylinder rod  39   a  pushes on the end block  26  in a manner similar to what is described in the embodiment of  FIGS. 1-7  above. The actuation rod  27   d  pivots around its pivot point which is now located at the intersection of the “l” where the rod  27   d  is pinned to the end block  26 , and applies downward force of the journal  120 . The journal  120  translates the downward force onto the material folder  131   a,  and also translates the downward force to the additional actuation rods  27   b  and  27   c.  The translated force on the additional actuation rods  27   e  and  27   f,  applied in a transverse direction relative to the downward force, causes the additional material folders  131   b  and  131   c  to move outwardly away from the actuation rods  27   e  and  27   f  (see  FIG. 10 ). The movement of the material folders  131   a,    131   b,  and  131   c  corresponding to the actuated position of the sub-assembly  109  in turn pulls, stretches, or otherwise tensions the free end portions  56  of the trim/material  55  about the edge  24   a  and inner portion  24   b  of the substrate  24  in a manner similar to what occurs in the embodiment of  FIGS. 1-7 . Finally, and similar to the embodiment of  FIGS. 1-7 , a fastening mechanism such as a stapler  70  may then be utilized to secure the free end portions  56  of the trim/material  55  to the inner portion  24   b  of the substrate  24 . 
     While also not illustrated, the embodiment of the automated wrapping system  20  provided in  FIGS. 8-10  also may also use a platen or pressure plate  45  as a part of the automated wrapping system  20  to apply pressure against the interior surface of the substrate  24  in the manner described in the first embodiment above in  FIGS. 1-7 . 
     In yet another alternative embodiment, as illustrated in  FIGS. 11-13 , the material folding system  25  includes a modified sub-assembly  119  that moves from a rest position to an engaged position. The sub-assembly  119  includes a number of operative components that were previously described with respect to the sub-assembly  39  of  FIGS. 1-7  above (with those common components referred to by the same reference number as in the embodiment above), as well as additional or different components as described below, but can include more or less components without deviating from the overall scope of the invention. The actuation rod  27  and end block  26  have been replaced by a cam slide type of arrangement for moving the material folder  31  and slide folder  30 . 
     In particular, as illustrated in  FIGS. 11-13 , the sub-assembly  119  includes a cam wheel  122  pivotally coupled to a cam end block  124 , with the cam end block  124  being coupled to the biasing slide  34 . The sub-assembly  119  also includes a ramp  130  fixedly coupled to the connector  32  and seated on the biasing slide  34  between the end block  124  and the material folder  31 . The ramp  130  has a bottom surface  132  positioned adjacent to the biasing slide  34  and an upper inclined surface  134  extending transverse to, and away from, the biasing slide  34  and an inner edge  133  of bottom surface  132 . Preferably, the contour of the bottom surface  132  corresponds to the corresponding contour of the biasing slide  34 , and most preferably the contour of the bottom surface  132  and the corresponding portion of the biasing slide  34  are flat. The upper inclined surface  134  terminates into a stop portion  136  having a flange portion  137  extending in a direction transverse to the upper inclined surface  134  in a direction away from the biasing slide  34  and bottom surface  132 . 
     The ramp  130  also includes a lower inclined surface  138  extending transverse to, and away from, the biasing slide  34  that connects to the stop portion  136  along an outer edge  140 . In certain embodiments, a plane defining the lower inclined surface  138  is parallel to a plane defining the upper inclined surface  134 , while in other embodiments the planes may extend in a non-parallel arrangement. A terminal portion  142  of the lower inclined surface  138 , located near the outer edge  140 , is seated onto an upper connector surface  139  of the connector  32 . A cam spring  151  is positioned between an inner portion  144  of the lower inclined surface  138  and the biasing slide  14 , with the inner portion  144  located between the terminal portion  142  and bottom surface  132 . 
     The cam wheel  122  is positioned on an upper inclined surface  134  of the ramp  130  and is configured to ride along the upper inclined surface  134  towards, or away, from the stop portion  136 , depending upon whether the sub-assembly  119  is moving towards the rest position (see  FIGS. 11 and 12 and 12A ) or actuated position (See  FIG. 13 ). A cam spring  151  is positioned between an inner portion  144  of the lower inclined surface  138  and the biasing slide  34 , with the inner portion  144  located between the terminal portion  142  and bottom surface  132 . The continuous biasing by the cam spring  151  automatically maintains the requisite force of ramp  130  against the cam wheel  122  regardless of the positioning of the cam wheel  122  on the upper inclined surface  134 . 
     The actuator  46 , here a hand actuating device  40  including a handle  41  and linkage  42 , is remotely connected to the cam end block  124  to provide the actuation of the material folder  31 . The actuation of the handle  41  by a user moves the linkage  42  to apply force that is translated to the cam end block  124  to move the cam end block  124  longitudinally in a direction towards the material folder  31  (shown by arrow  157  in  FIG. 13 ), thereby causing the coupled cam wheel  122  to move along the upper inclined surface  134  of the ramp  130  in a direction towards the stop portion  136 . The movement of the cam wheel  122  longitudinally towards the stop portion  136  applies force on the upper inclined surface to move the ramp  130  in a direction towards the biasing slide  34  that compresses the cam spring  151 . The force applied to the upper inclined surface  134  to move the ramp  130  is translated to the upper connector surface  139  of the connector  32  to move the connector  32 , which in turn causes the material folder  31  (shown by arrow  159  in  FIG. 13 ) coupled to the connector  32  to move downward such that the sub-assembly  119  is moved to the actuated position to hold, fold, pull and otherwise tension and secure the free end portion  56  of the trim/material  55  to the inner portion  24   b  of the substrate  24  while the retaining section  44  holds the material  55  against the edge  24   a  of the substrate  24  in the same manner as described above with respect to the movement of the sub-assembly  39  of the first embodiment to the actuated position as described in  FIGS. 1-6  above, including wherein the biasing slide  34  is moved to an operational or biasing position such that that retainer section  44  engages the free end portion  56  of the material  55  extending outwardly from the nest  21  to hold this free end portion  56  of the material  55  in position against an edge  24   a  of the substrate  24  prior to the movement of the material folder  31  to the actuated position. The biased position and rest position, wherein the retainer section  44  of the biasing slide  34  is positioned to hold the material  55  against the edge  24   a  of the substrate but wherein the material folder is in raised position corresponding to the rest position, is illustrated in  FIG. 12A  wherein the free end portion  56  is folded over the edge  24   a  of the substrate  24  but is not positioned against a part of the inner portion  24   b  of the substrate  24 . 
     Once in the actuated position and wherein the biasing slide  34  is in the biased position (see  FIG. 13 ), and similar to the description above in the first embodiment in  FIG. 7 , a fastening mechanism such as a stapler  70  can be used to secure the free end portion  56  of the trim/material  55  to the inner portion  24   b  of the substrate  24  with staples  74  or a similar fastening device as also described above. 
     As noted above, the illustrated embodiment of  FIGS. 11-13  include a hand actuating device  40  as the actuator  46 . However, an actuator  46  as in  FIGS. 1-7 and 8-10 , including the air cylinder  38  and air cylinder mount  37 , could also be utilized as the actuator  46  in the embodiment of  FIGS. 11-13 . Similarly, the hand actuating device  40  can be utilized as the actuator  46  in the embodiments as in  FIGS. 1-7 and 8-10 . 
     While also not illustrated, the embodiment of the automated wrapping system  20  provided in  FIGS. 11-13  may also use a platen or pressure plate  45  as a part of the automated wrapping system  20  to apply pressure against the interior surface of the substrate  24  in the manner described in the first embodiment above in  FIGS. 1-7 . 
     In still another alternative embodiment of the subject invention, as provided in  FIGS. 14-15 , the material folding system  25  includes a sub-assembly  155  that includes a wheel assembly  159  including one or more wheels  180  which contact the free end portion  56  of the material  55  and fold the material over the edge  24   a  of the substrate and onto the inner portion  24   b  in a similar manner to the material folders  31 ,  131   a,    131   b,    131   c  of the embodiments shown in  FIGS. 1-13  above. 
     In particular, the material folding system  25  as illustrated in  FIGS. 14-15 , includes a moveable sub-assembly  155  coupled to a base  160 , with the sub-assembly  155  moveable between the rest position and the actuated position in a manner similar to the previous embodiments described above in  FIGS. 1-13 . 
     In general, the sub-assembly  155  of the embodiment of  FIGS. 14-15  includes a wheel assembly  159  which includes one or more wheels  180 . The actuator  46  is connected to the wheel assembly  159  and is configured for sliding and pivoting the wheel assembly  159  relative to the base  160  between a wheel non-engaged state and a wheel engaged state, with the wheel non-engaged state corresponding to the rest position and the wheel engaged state corresponding to the actuated positon. The movement of the wheel assembly  159  from the wheel non-engaged state to the wheel engaged state causes the one or more wheels  180  to engage and fold the free end portion  56  of the material  55  over the edge  24   a  of the substrate  24  and onto inner portion  24   b  of the substrate  24 , as will be described in further detail below. 
     In particular, the wheel assembly  159  includes a motor  162  coupled to, and preferably affixed to, a top surface  161  of the base  160  through one or more adjustment screws  162   a.  A shaft retainer  164  is slidably coupled to the top surface  161  of the base  160  and is slidable relative to the top surface  161  of the base  160  in a longitudinal direction toward or away from the nest  21  between a first retainer position (see  FIG. 14 ) and a second retainer position (see  FIG. 15 ). 
     As illustrated, the shaft retainer  164  includes a pair shaft retainers portions  165 ,  166  extending from, and secured to, a rearward shaft connector  164   a.  Each shaft retainer portion  165 ,  166  includes two or more spaced apart flanges  167  extending from a rearward plate portion which is aligned with, and preferably fixed to, the rearward plate portion. Each of the flanges  167  includes axially aligned openings  168 . 
     The sub-assembly  155  also includes a first wheel shaft  170  that is coupled through the axially aligned openings  168  of the flanges  167  within the first shaft retainer portion  165 , and an additional first wheel shaft  171  that is coupled through the axially aligned openings  168  of the flanges  167  within the second shaft retainer portion  166 . 
     The sub-assembly  155  also includes one or more wheel links  173  pivotally coupled to the first shaft wheel shaft  170 , and one or more wheel links  174  pivotally coupled to the additional first shaft wheel shaft  171 , with each of the wheel links pivotally coupled to the respective wheel shaft  170 ,  171  between a respective adjacent pair of the two or more flanges  167 . 
     In particular, each of the wheel links  173 ,  174  has a first opening that respectively receive one of the first shaft wheel shafts  170 ,  171  and also include a second opening remote and opposite from the first opening that receives a respective one of a second wheel shaft. Accordingly, each of the wheel links  173  is pivotally coupled to the first wheel shaft  170  and the second wheel shaft  181 , while each of the wheel links  174  is pivotally coupled to the first wheel shaft  171  and the second wheel shaft  182 . 
     As noted above, the wheel assembly  159  also includes one or more wheels  180 . In particular, and as illustrated in  FIGS. 14-15 , a plurality of wheels  180  are coupled to each one of the respective second wheel shafts  181 ,  182 . In certain embodiments, such as illustrated in  FIGS. 14-16 , the number of wheels  180  on each second wheel shafts  181 ,  182  corresponds to the number of wheel links  173 ,  174  pivotally coupled to each second wheel shaft  181 ,  182 , while in other embodiments the number of wheels  180  may be different than the number wheel links  173 ,  174 . 
     The wheel assembly  159  also includes a drive cable  190  that is coupled to each one of the respective second wheel shafts  181 ,  182  and to the motor  162 . Accordingly, upon actuation of the motor  162 , the respective second wheel shafts  181 ,  182  rotate in a first rotational direction, or in a second rotational direction opposite the first rotational direction. 
     As noted above, the automated wrapping system  20  in the embodiment of  FIGS. 14-15  also includes an actuator  46 . In particular, the actuator  46  is in the form of a cylinder  38  having a cylinder support  37  seated on the base  160 . The cylinder  38  includes a cylinder rod  38   a  that is secured through the rearward shaft connector  164   a  of the shaft retainer  164  with a cylinder nut. In alternative embodiments, the actuator  46  could be in the form of a hand actuation device  40  as described above with respect to the embodiment described in  FIGS. 11-13 . 
     The wheel assembly  159  may also include a wheel rest  190  that is coupled to an end portion of the base  160  at a position adjacent to the nest  21 . When the sub-assembly is in the rest position, the one or more wheels  180  are positioned adjacent to a top surface  192  of the wheel rest  190 . 
     When the actuator  46  is actuated to move the sub-assembly  155  from the rest position to the actuated position, the wheel assembly  159  in turn is moved from the wheel non-engaged state to the wheel engaged state. In particular, the cylinder rod  38   a  of the actuated actuator  46  is extended outwardly in a direction towards the nest  21  and applies a force to the shaft retainer  164 . In response, the shaft retainer  164  slides along the base in a longitudinal direction from the first retainer position (see  FIG. 14 ) to a second retainer position (see  FIG. 15 ). The sliding movement of the shaft retainer  164  towards the nest  21  in turn moves the first wheel shafts  170 ,  171 ; the wheel links  173 ,  174 ; the second wheel shafts  180 ,  181 ; and the wheels  180 . In particular, the wheels  180  and coupled second wheel shafts  181 ,  182  are extended outward beyond the end of the wheel rest  190  and over the nest  21  and are brought into contact with the free end portion  56  of the material  55  at a position generally above the edge  24   a  of the substrate  24  when the sub-assembly  155  is placed in the actuated position. Once beyond the end of the wheel rest  190 , the wheels  180  begin to move downward due to the force of gravity as well as outward from the wheel rest  190 , with the downward and outward movement controlled by the pivoting of the wheel links  173 ,  174  about their respective pivot points corresponding, respectively, at one end about the length of the first wheel shafts  170 ,  171  and at the opposing end by the length of the second wheel shafts  181 ,  182 . The continued outward and downward movement of the wheels  180  folds the free end portion  56  of the material  55  over the edge  24   a  of the substrate  24  such that it is brought into contact with the inner portion  24   b  when the sub-assembly  155  reaches the actuated position. 
     Once the sub-assembly  155  is in the actuated position, corresponding to the wheel engaged state of the wheel assembly  159 , the motor  162  may then be actuated. The actuation of the motor  162  causes the coordinated rotation of the second wheel shafts  181 ,  182  (and the coupled wheels  180 ) through the drive cable  190  in either a first rotational direction or a second rotational direction opposite the first rotational direction. 
     When rotating in the first rotational direction, the wheels  180  engage the free end portion  56  of the material  55  to move in a first direction along the inner portion  24   b  of the substrate  24  away from the edge  24   a,  resulting in the stretching of the free end portion  56  portion of the material  55  in the first direction away from the edge  24   a  to create a tighter fit of the material  55  against the inner portion  24   b.  In addition, the remainder of the material  55  may also be stretched against the edge  24   a  and outer surface  24   b  of the substrate  24 , resulting in a tighter fit of the material  55  to the substrate  24 . When rotating in the second rotational position, the wheels  180  cause the free end portion  56  to move along the inner portion  24   b  in a direction towards the edge  24 , creating a looser fit of the material  55  to the substrate  24 . To determine whether to rotate the wheels  180  in either the first or second direction, a visual observation by the operator may be utilized to determine the fit of the material  55  to the substrate  24 . Alternatively, and preferably, the alignment system  75  (with the vision system  77  and camera system  79 ) to view the stitching of the material relative to the substrate  24  may also be used to more precisely determine whether an adjustment of the tension, accomplished by rotation of the wheels  180 , is desired. Accordingly, this embodiment provides a method therefore for enhancing the fit of the material  55  to the substrate  24  during the wrapping process. 
     Once in the actuated position and wheel engaged position, and wherein the free end portion  56  of the material  55  has been stretched by rotation of the wheels  180  in either the first or second rotational direction, as described above, and similar to the description above in the first embodiment in  FIG. 7 , a fastening mechanism such as a stapler  70  can be used to secure the free end portion  56  of the trim/material  55  to the inner portion  24   b  of the substrate  24 . 
     While also not illustrated, the embodiment of the automated wrapping system  20  provided in  FIGS. 14-15  also may also use a platen or pressure plate  45  as a part of the automated wrapping system  20  to apply pressure against the interior surface of the substrate  24  in the manner described in the first embodiment above in  FIGS. 1-7 . 
     Referring now to  FIGS. 16-19 , yet another alternative embodiment of the automated wrapping assembly  20  is provided which includes material folding assembly  25  includes a modified sub-assembly  219  moveable between the rest positon and the actuated position to engage and fold the free end portion  56  of the material  55  to the substrate  55  in a similar manner to that described in the alternative embodiments above (the material  55  is omitted from  FIG. 19 ). In this embodiment, a stretching device  250  may optionally also be included that works in conjunction with the material folding assembly  25  to further stretch the free end portion  56  of the material  55  along the inner portion  24   b  prior to fastening, as will be described further below. 
     In this embodiment, the sub-assembly  219  is positioned on a base  220  that is located adjacent to the nest  21 . Referring now to  FIGS. 16-18 , the sub-assembly  219  includes an end block  222 , preferably an l-shaped end block  222 , having a first leg  224  extending in a direction towards the base  220  and a second leg  226  extending transverse to the first leg  224 . In certain embodiments, the length of the second leg  226  is parallel to the length of the base  220 . The actuator  46 , here an air cylinder  38  having the cylinder rod  38   a,  is mounted to an air cylinder mount  37  which is seated on the base  220 . The air cylinder  38  is connected to the first leg  224  of the end block  222  via the cylinder rod  38   a  and is configured to move the end block  222  towards, or away from the nest  21  between a first block position and a second block position. The first block position (see  FIG. 18 ) corresponds to the rest position of the sub-assembly  219 , while the second block position (see  FIG. 19 ) corresponds to the actuated position. 
     The sub assembly  219  also includes a base block  228  that is coupled to, and preferably disposed on, the end block  222 . A slide block  230  is adjustably and fixedly coupled to the base block  228  using an adjustable fastener  232 , best illustrated in  FIGS. 18 and 19  as a screw. The slide block  230  has a retainer section  234  configured for engaging the material  55  and holding the material  55  against an edge  24   a  of the substrate  24 . Similar to the retainer section  44 , the retainer section  234  can include a contoured engagement surface to enhance the gripping of the material  55  along the edge  24   a  of the substrate 
     The sub assembly  219  also includes an l-shaped flange  236  pivotally coupled to the slide block  230  with a pin  238 . The l-shaped flange  236  is pivotable about the length of the pin  238  (i.e., is pivotally moveable relative to the slide block  230 ) between a first pivoted position (see  FIG. 16 ) and a second pivoted position (see  FIG. 17 ). An l-shaped bracket  240  is seated on a top surface of the slide block  230 . In particular the l-shaped bracket  240  includes a first leg  244  seated on the top surface of the slide block  230  and a second leg  246  extending transverse to the first leg  244  in a direction away from the slide block  230  and base  220 . A spring  242  is coupled between the l-shaped flange  236  and the second leg  246  of the l-shaped bracket  240 . 
     The stretching device  250 , as best shown in  FIG. 16-18 , includes a pivotable assembly  252  pivotally moveable between a non-engaged position (see  FIGS. 16 and 17 ) and an engaged position (see  FIGS. 18 and 19 ). 
     The stretching device  250  has a linear actuator  252  that is coupled to a linkage  254  having a first arm  256  pivotally coupled to a second arm  258 . An additional linkage  260  is pivotally coupled to the second arm  258 . A biasing arm  264  is pivotally coupled to the additional linkage  260  and includes a finger portion  266  and an opposing spring biasing portion  268 . A spring  270  is disposed between the second arm  258  and the spring biasing portion  268 . The finger portion  266 , when the stretching device  250  is in the engaged position and when the sub-assembly  219  is in the actuated positon, is configured to press against the free end portion  56  of the material  55  against the inner portion  24   b  of the substrate  24  to stretch the material  55  along the inner portion  24   by  of the substrate  24 . 
     The operation of the automated wrapping assembly  20 , in accordance with the embodiment of  FIGS. 16-19 , is as follows. First, the material  55  and substrate  24  are placed on the nest  21  in accordance with the manner described in each of the previous embodiments of  FIGS. 1-15 . Next, the alignment system  75  can be utilized to confirm that the material  55  is properly aligned as also described above. Next, and optionally, the platen  45  may be lowered onto the substrate  24  and material  55  within the nest  21  as described in the embodiments as described the embodiments above. 
     Next, the actuator  46  is actuated to move the material folding system  25  and sub-assembly  219  from the rest position to the actuated position, wherein the cylinder rod  38   a  of the air cylinder  38  contact and applies force to the first leg  224  of the end block  222  to move the end block  222  in a direction towards the nest  21  from a first block position (see  FIG. 16 ) to the second block position (see  FIGS. 17 and 18 ). The movement of the end block  222 , in turn, moves the slide block  230  such that the retainer section  234  is positioned against the material  55  at a position corresponding to the edge  24   a  of the substrate  24 . The movement of the slide block  230  also causes the pivoting movement of the l-shaped flange  236 , wherein a first leg  237  of the l-shaped flange  236  contacts the free end portion  56  of the material  55  and folds the material  55  over the substrate edge  24   a . The movement of the l-shaped flange  236  pivots the l-shaped flange  236  around an axis defined by the length of the pin  238 , thereby folding the free end portion  56  onto the inner portion  24   b  (see also  FIG. 17 ) and positioning the first leg  237  such that the free end portion  56  is between the first leg  237  and the inner portion  24   b  of the substrate  24 . During this pivoting movement, the spring  242  is stretched between the l-shaped flange  236  and second leg  246  of the l-shaped bracket  240  to accommodate the pivoting movement. 
     While the embodiment as illustrated in  FIGS. 16-18  illustrates the contacting of the l-shaped flange  236  to the free end portion  56  of the material  55  prior to the positioning of the retainer section  234  being positioned adjacent to the edge  24   a  of the substrate  24 , in alternative embodiments the l-shaped flange  236  is coupled such that it contacts the free end portion  56  of the material simultaneous with or after the retainer section  234  being positioned adjacent to the edge  24   a  of the substrate  24 . Accordingly, in instance wherein the retainer section  234  is first engaged, the retainer section  234  first holds the material  55  against the edge  24   a  of the substrate  24  prior to the l-shaped flange  236  engaging the free end portion  56  to fold the free end portion  56  over the edge  24   a  and into contact with the inner portion  24   b  of the substrate. 
     Next, and optionally, the alignment system  75  can be reactivated to confirm that the material  55  remains properly positioned after the actuation step. If the material  55  is not properly aligned, the sub-assembly  219  can be moved back to the rest position, and the material  55  realigned relative to the substrate  24 . If the material  55  remains properly aligned as determined by the alignment system  75 , the stretching device  250 , where utilized, can be moved from the non-engaged position (see  FIGS. 16 and 17 ) to the engaged position (see  FIGS. 18 and 19 ). 
     In the engaged position, as shown in  FIGS. 18 and 19 , the assembly  252  is pivoted such that the finger portion  266  is engaged with the free end portion  56  of the material  55  opposite the inner portion  24   b.  The linear actuator  252  is then engaged to apply force to the first arm  256  of the linkage  254 . The force to the first arm  256  pivots the second arm  258  at the pivot point, with the force then translated to the biasing arm  264 , which pivots and moves slightly in a first direction (shown by arrow  271  in  FIG. 18 ) to press the finger portion  266  into the free end portion  56  of the material  55  (the free end portion  56  and material  55  are omitted from  FIG. 19 ) and pull the free end portion  56  of the material  55  away from the edge  24   a  along the inner portion  24   b  of the substrate. The spring  242  stretches slightly between the spring biasing portion  268  and the second leg  258  to accomplish this pivoting and first directional movement. 
     Next, and optionally, the alignment system  75  can be reactivated to confirm that the material  55  remains properly positioned relative to the substrate  24  after the free end portion  56  has been folded and stretched as described above. Finally, the fastening mechanism may be utilized to secure the free end portion  56  of the material  55  to the inner portion  24   b  of the substrate  24  in a manner described above. 
     The present invention thus provides a safer, more accurate, simpler, worker health conscious, efficient, faster, more economic and financially advantageous method to wrap, align, stretch and fasten material over substrates. The general method of operation, which can be utilized in any of the embodiments described above, is as follows. The trim/material  55  is loaded into the nest  21  while the vacuum, if utilized, is operational. The stitching on the material  55  is aligned, and the location of the stitches  83  (see  FIG. 5 ) of the material  55  is checked, and re-checked after any necessary adjustment. The vision system  77 , and/or camera system  79 , used in the alignment system  75  (when present), may provide a green light or some form of feedback indicating that the material  55  is properly aligned on the nest  21 . The substrate  24  is then loaded against the trim/material  55 . The alignment of the stitching is optionally re-checked. The vision system  77  and/or camera system  79 , used in the alignment system  75  (when present) may provide a green light or some form of feedback indicating that the material  55  remains properly aligned on the nest  21 . 
     The platen  45 , if utilized, is then lowered into position to apply the desired pressure to the substrate  24 . The material folding assembly  25  is then activated, wherein the actuator  46  moves the sub-assembly (as provided in various forms in the embodiments described above) from the rest position to the actuated position. The platen  45 , and the material folding system  25 , could be activated simultaneously, or in any suitable sequence. The retainer section (such as the retainer section  44  or  234  in certain of the embodiments described) of the biasing slide is positioned in an operational or biasing position to hold the material  55  against the edge  24   a  of the substrate. Next, the material folding assembly and associated sub-assembly is moved to the actuated position, and a portion of the sub-assembly which holds, folds, pulls and otherwise tensions and secures the trim/material  55  to the substrate  24  (such as the material folder  31 ,  131   a,    131   b,    131   c  in the embodiments described in  FIGS. 1-13 ; the one or more wheels  180  in  FIGS. 14-15 , or the l-shaped flange  236  in  FIGS. 16-19 ). The platen  45  is then preferably raised/retracted. An optional stretching device can then be positioned and stretch the free end portion  56  of the material  55  prior to fastening. The fastening mechanism, such as the stapler  70 , is moved into position, either manually or automated, to secure the free end portions  56  of the material  55  to the substrate  24  using a fastening device such as a staple  81 . After the material  55  is secured to the inner portion  24   b  of the substrate  24 , the material folder  31  is retracted to the rest position and the retainer section, in certain embodiments, is withdrawn to a non-operational or non-biasing position. The finished part  100 , having the material  55  secured to the substrate  24 , can now be removed from the nest  21 . 
     The invention provided in the various embodiments herein provides an automated wrapping system to wrap, align, stretch and fasten material over substrates to form a wide variety of parts. The devices and methods provided herein are more accurate, simpler, more efficient, faster, more economic and financially advantageous as compared to traditional method and devices that typically utilize hand wrapping and fastening. Moreover, the elimination of hand wrapping and fastening enhances worker safety. Still further, the resultant parts, by virtue of their tighter wrapping, typically have an enhanced visual aesthetic appearance as compared with hand-wrapped parts with looser wrapping. 
     The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described.