Patent Document

BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates to a wrapping apparatus and more particularly to a shuttle or wrapping material carrier change system and method for a wrapping apparatus. 
         [0002]    Certain items are packaged in roll or coil form. For example, steel and aluminum sheet are often coiled for storage, transport, and handling. Such coils can be up to five to seven feet in diameter. 
         [0003]    In order to protect and preserve the appearance of the steel or aluminum, the coils are typically wrapped with protective material in the form of a film. Such a film can be a single wrap of, for example, a low density polyethylene stretch film. The wrap can also include a fabric or other woven or non-woven material wrapped along with the polyethylene film. 
         [0004]    One known machine for carrying out the wrapping process uses a specifically shaped track to carry a film dispensing shuttle through the eye of the coil, while the coil is slowly rotated on its axis on a set of block rollers. The complete body of the coil is effectively sealed by a cocoon of stretch film. 
         [0005]    Generally, the machine has a heavy-duty, generally oval shaped track that provides the guide for the film-dispensing shuttle that travels around the inside of the track. The track has a hinged end section or arm that pivots upwardly to open the track so that a lower portion of the track can be moved into the eye of the coil. The track is adjustable in the vertical plane to accommodate different coil diameters. 
         [0006]    The track is typically movable on rails to advance into the eye of the coil. The machine can also be movable transverse to the direction of the track. Such a machine is commercially available from ITW Fleetwood-Signode of Glenview, Ill., under the name CoilMaster. 
         [0007]    The film dispensing shuttle is designed to drive itself around the track. In a present system the shuttle includes a drive element (referred to as a tractor) and one or more film dispensing elements (each referred to as a trailer). The tractor and trailers are separate from, but operably connected to one another such that the tractor drives (pulls) the one or more trailers, and so that the tractor and trailer(s) can be separated from each other for maintenance, repair, replacement or the like. 
         [0008]    The film is provided on the shuttle in rolls. The rolls have a finite amount of material wound thereon and as such require periodic replacement. Depending upon the size of the coil, a roll of film can last for perhaps as few as two or three coils. As such, the film rolls on the shuttle may have to be replaced fairly frequently. In known machines, the task of replacing the film and the shuttles is labor intensive and time consuming, thus quite costly. 
         [0009]    To replace a film roll, the machine has to be shut down and the hinged track end opened. If a “tail” of the film is hanging from the coil, the tail is tucked into the wound film to prevent the tail from interfering with movement of the shuttle. The shuttle is positioned along the track at a predetermined location and the track is then withdrawn from the coil. 
         [0010]    Following withdrawal of the track, a film roll is replaced in the shuttle. The track is then moved back into place in the eye of the coil, the hinged end is lowered and the track is closed. A leading end of the film is secured and the shuttle is restarted. Given that these machines are quite large, the entire film roll replacement procedure takes a considerable amount of time and requires a considerable amount of labor. 
         [0011]    Accordingly, there is a need for a system and method for changing out a shuttle that precludes the need to remove the track from the eye of the coil. Desirably, such a system and method are carried out with the track in place in the coil. More desirably, such a system and method uses a ready substitute shuttle to further reduce the downtime necessary to place the machine back into service. 
       BRIEF SUMMARY OF THE INVENTION 
       [0012]    A shuttle change system for use in a wrapping apparatus for wrapping an associated item is disclosed. The wrapping apparatus has an oval track vertically oriented with a cantilevered base portion and an openable portion in the track to move the item into and out of the track. The wrapping apparatus includes a shuttle that moves along the inner periphery of the track dispensing a wrapping material. The shuttle change system includes a carrier and a pair of track sections mounted to the carrier. The track sections are spaced from one another and parallel to one another, each adapted to support a shuttle. The carrier is moveable vertically, longitudinally, and laterally to align either of the pair of tracks with the cantilevered base portion of the track. One of the tracks is adapted to receive a shuttle to be replaced and the other of the tracks is adapted to store a replacement shuttle for movement onto the track. The carrier is movable away from the track to permit the openable track portion to open and close without interference. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0013]    The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein: 
           [0014]      FIG. 1  is a side view of a wrapping apparatus having a shuttle change system in accordance with the principles of the present invent; 
           [0015]      FIG. 2  is a top view of the apparatus of  FIG. 1 ; 
           [0016]      FIGS. 3A-3C  are front, side and top views, respectively, it the shuttle change assembly; 
           [0017]      FIG. 4  is a front-side perspective view of the wrapping apparatus with the apparatus being retracted from a wrapped coil; 
           [0018]      FIG. 5  is a rear-side perspective view of the wrapping apparatus with the shuttle in the home position, with the films clamped in the cutter-clamp and the cutter clamp in the plane of the track; 
           [0019]      FIG. 6  is also a rear-side perspective view of the wrapping apparatus with the shuttle in the home position, with the films clamped in the cutter-clamp, but with the cutter clamp moved out of the plane of the track; 
           [0020]      FIG. 7  is more of a side perspective view of the wrapping apparatus showing the shuttle in the home position, this shuttle having a tractor (the drive system) integrated with the trailers (the film dispensers); 
           [0021]      FIG. 8  is a rear-side perspective view of the wrapping apparatus as seen from the side opposite of that shown in  FIGS. 4-7 , better showing the cutter-clamp assembly; and 
           [0022]      FIG. 9  is a rear-side perspective view of the wrapping apparatus showing the shuttles moving around the track and showing the coil partially wrapped. 
       
    
    
     DESCRIPTION OF THE INVENTION 
       [0023]    While the present invention is susceptible of embodiment in various forms, there is shown in the figures and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated. 
         [0024]    Referring to the figures and in particular to  FIG. 1  there is shown a wrapping apparatus or machine  10  having a shuttle change system  12  and carrying out a method for shuttle change embodying the principles of the present invention. 
         [0025]    The machine  10  includes a track  14  having a generally oval shape. A lower portion  18  of the track  14  is cantilevered when the arm  20  is open. An end (or arm)  20  of the oval is hinged opposite of the base  16  (with the hinge  22  at about the top of the track  14 ) to permit the track to be opened. When closed, the arm  20  aligns with the lower portion  18  of the track  14 . The inside or inner periphery  24  of the track  14  thus defines a substantially continuous track. The track  14  moves up and down to accommodate coils C of different diameters. 
         [0026]    A shuttle  26  is configured for movement along the inner periphery  24  of the track  14  in the direction indicated by the arrow at  28 . The shuttle  26  includes, in a present embodiment, a drive or tractor  30 , and a pair of film dispensing cars or  32   a,b  trailers that are pulled along by the tractor  30 . Each of the trailers  32  dispenses either a polymer film, e.g., a low density polyethylene film or a fabric or like wrapping member, collectively referred to as film or films F. It should be noted that  FIGS. 4-9  show a tractor that is integral with the trailer. 
         [0027]    The change system  12  is configured to permit removing the shuttle  26  from the track  14  and replacing the shuttle  26  with a ready, stand-by or replacement shuttle  26 ′ (see  FIG. 1 ), with the track  14  in place in the eye E of the coil C. In fact, of the track  14  itself, only the arm section  20  of the track  14  has to be moved (i.e., opened) in order to effect a change of the shuttle  26 . In addition, the shuttle  26  can be changed with a coil in place in the wrapping machine  10 . 
         [0028]    The change system  12  includes an assembly  36  having at least a pair of side-by-side track sections  38   a,b  on which the shuttle  26  can ride. The change system track sections  38  are oriented parallel to the machine track  14 . In a present embodiment, the change system sections  38   a,b  are mounted to a carrier  40  that is adjustable in a number of planes. First, the change system track sections  38  height can be adjusted to match that of the machine track  14  (which can be positioned at different elevations depending upon the outside diameter of the coil C being wrapped. The longitudinal orientation (as indicated by the arrow at  42 ) can be changed to move the track sections  38  toward and away from the machine track  14 , and the track sections  38  can be moved laterally or transverse (as indicated by the arrow at  44 ) to the machine track  14  direction so that the change system track sections  38  can align with the machine track  14 . A winder element  46  is associated with each set of track sections  38  that, as will be discussed below, winds a portion of the film or films F after a new shuttle  26 ′ has been positioned on the track  14 , but before it is placed in service, to remove any excess film(s) or film tail from the track  14  surface. 
         [0029]    As set forth above, the change system  12  includes at least a pair of track sections  38   a,b . In this manner, a replacement shuttle  26 ′ can reside on one of the track sections, for example,  38   a , and the other track section  38   b  can be vacant. As will be discussed in more detail below, and as will be appreciated, the to-be-replaced shuttle  26  can be moved onto the vacant track section  38   b  and the replacement shuttle  26 ′ can be readily moved onto the machine track  14 . 
         [0030]    To assist with changing the shuttles  26 , the machine  10  includes a cutter-clamp assembly  48  that is mounted at about the machine track  14  or the base  16 . The cutter-clamp assembly  48  moves with the machine track  14  rather than the change system track sections  38 . When in use, the cutter-clamp  48  is disposed within the interior of the machine track  14  (within the plane P 14  of the track  14 ), but outside of the coil C—that is, between the machine track  14  and/or the shuttle  26  and the coil C. Again, when in use, the cutter-clamp  48  is stationary relative to the track, and is configured to hold or secure (e.g., anchor) a free end of the film F as the shuttle  26  moves about the track  14  when the shuttle  26  begins wrapping film F round the coil C. The cutter-clamp assembly  48  moves into and out of the loop (or the plane P 14  of the track  14 ) for use. A clamp element  50  of the cutter-clamp  48  is on the shuttle  26  side or downstream side of the assembly  48  and a cutter element is  52  on the upstream side of the assembly  48  (the side close to the winder  46 ). 
         [0031]    Operation of the machine  10 , the wrapping cycle, as well as the shuttle  26  replacement cycle can be controlled by a controller or control system  54  which can be fully automated. 
         [0032]    A cycle of the wrapping operation will be discussed with reference to a single wrapping machine  10  with a shuttle change system  12  having one pair of change system track sections  38   a,b . Also for purposes of the present discussion, the description of the “cycle” will begin with the coil C in the process of being wrapped. 
         [0033]    The coil C is loaded on a set of rollers to rotate the coil C. The rollers  56  are positioned such that the eye E of the coil C is aligned with the machine track  14  and the shuttle  26  is traversing around the track  14  wrapping the coil C with the film(s) F (see  FIG. 9 ). The cutter-clamp  48  is positioned (moved) to the side of the machine  10  outside of the plane P 14  of the track. 
         [0034]    The shuttle change assembly  36  is positioned laterally next to the coil C that is being wrapped. At this point in time the shuttle change assembly  36  has one open or empty track  38   b  and a replacement shuttle  26 ′ on the second track  38   a . The leading end(s) of the film(s) F on the replacement shuttle  26 ′ are held by the winder element  46 . 
         [0035]    The assembly  36 , as set forth above, includes at least a pair of tracks  38   a,b —more than two tracks can be included, but are not necessary. The assembly  36  height is adjusted (vertical adjustment), by, for example, a motor and lift  58 , to match the height of the shuttle system track sections  38  to the height of the machine track  14 . 
         [0036]    When the shuttle  26  runs out of film(s) F it moves to a home position H which in a present machine is along a portion of the upward curve of the oval, opposite of the arm  20 . The home position H is reached by continuing in the forward direction  28  only. The shuttle  26  then continues in the forward direction  28 , beyond the location  60  where the arm  20  joins the lower track portion  18 , to a position on the lower track portion  18 . It will be appreciated that when the shuttle  26  runs out of film(s) F, a film&#39;s tail may be left hanging from the coil C. If the tail is hanging and rests on the track, it could get caught under the shuttle and interfere with movement of the shuttle. As such by moving the shuttle  26  in this way, if a tail of the film(s) is left hanging from the coil C, the shuttle  26  will pass under the tail (between the tail and track  14 ). Accordingly, the tail will rest, if at all, on the top of the shuttle  26 . This prevents the tail from becoming caught under the shuttle  26  (in the shuttle wheels  62 ). 
         [0037]    After the shuttle  26  moves into this position, the track hinged section or arm  20  opens. The shuttle assembly  36  moves laterally toward the lower track section  14  to align the empty shuttle track  38   b  with the lower track section  14  and longitudinally to engage the empty shuttle track  38   b  with the machine track  14 . The empty shuttle  26  then moves onto the empty track  38   b.    
         [0038]    The assembly  36  then moves longitudinally away from the lower track  14  to disengage from the track  14  and moves laterally to align the replacement shuttle track  38   a  with the lower track section  14 . The assembly  36  then moves longitudinally to reengage the tracks  14 ,  38   a . The replacement shuttle (not shown) moves onto the machine track  14  into the home position H. 
         [0039]    The assembly  36  then again moves longitudinally away from the track  14  to disengage from the track  14  and laterally away from the track  14  so that they are no longer aligned. The arm  20  then pivots back down to engage (and lock into) the track  14 . The track  14  is now closed and the shuttle  26 ′ in the home position H. It will be understood that the end of the film(s) is held by the winder  46  and thus extends from the shuttle  26 ′ through the eye E of the coil C, to the winder  46 . 
         [0040]    The cutter-clamp assembly  48  then moves into place (moves into the plane P 14  as shown in  FIG. 2  of the track  14 ), such that the films(s) F are in the jaws  54  of the assembly  48 . It will be remembered that the cutter  52  is on the winder  46  side of the assembly  48  and the clamp  50  is on the shuttle  26  side of the assembly  48 . The cutter element  52  is actuated to sever the feed film(s) F from the cutter clamp  48 . The winder  46  is actuated to rewind any tail attached to it back to itself. This clears the coil C eye E for unobstructed shuttle  26 ′ movement. 
         [0041]    The shuttle  26 ′ then commences or re-commences wrapping the coil C. After a few seconds of shuttle  26 ′ movement, the cutter-clamp  48  moves out of the plane P 14  of the track  14 . Then, after a predetermined number of winds around the coil C (when it has been determined that the film(s) F will remain on the coil C and will not be pulled off), the clamp element  50  is opened to allow the cycle to continue until the coil C wrap is completed or the shuttle  26 ′ runs out of film(s) F. 
         [0042]    It will be appreciated that the present systems  10 ,  12  anticipate greatly reduced operator time and labor for operation. Accordingly, most if not all of the steps necessary to the above-noted cycle of operation (method) can be carried out automatically using known control systems  54  and methods. In addition, although the machine  10 ,  12  and operation are described based upon a single wrapping machine  10  that is fixed to a location, the present change system  12  can be used in conjunction with wrapping machines with multiple rollers stations that move (for example, along rails  66 ) transverse to the track  14  direction. All such variations on the systems  10 ,  12  are within the scope and spirit of the present invention. 
         [0043]    All patents referred to herein, are hereby incorporated herein by reference, whether or not specifically done so within the text of this disclosure. 
         [0044]    In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. 
         [0045]    From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover all such modifications as fall within the scope of the claims.

Technology Category: 4