BAGGER SYSTEM AND METHOD OF OPERATION

Abstract

Systems and methods for a bagger are provided. The bagger includes a support frame including two rails; a movable system configured to receive a film therethrough, the movable system including a seal system, a gripper system, and a cutting device, the movable system attached to the two rails of the support frame; actuators including a first actuator and a second actuator, the first actuator and the second actuator each configured to move the movable system along a respective rail of the two rails of the support frame, simultaneously; and a roller configured to hold a roll of the film, the roller connected to a portion of the support frame.

Description

FIELD

Embodiments of the present disclosure are directed to a bagger system and method of operation thereof.

SUMMARY

According to one or more embodiments, a bagger is provided. The bagger includes: a support frame including two rails; a movable system configured to receive a film therethrough, the movable system including a seal system, a gripper system, and a cutting device, the movable system attached to the two rails of the support frame; actuators including a first actuator and a second actuator, the first actuator and the second actuator each configured to move the movable system along a respective rail of the two rails of the support frame, simultaneously; and a roller configured to hold a roll of the film, the roller connected to a portion of the support frame, wherein wherein the gripper system includes at least one body that is configured to grip the film, the seal system includes a seal bar that is configured to heat seal opposite side faces of the film together so as to form a first end of a bag, and the cutting device includes an actuator and a knife, the actuator configured to cause the knife to separate the bag from another portion of the film by cutting the film.

According to one or more embodiments, a method of forming a bag from a film by using a bagger is provided. The method includes: controlling a movable system of the bagger to move a predetermined amount in a first direction to a first position while a gripper system of the movable system and a seal system of the movable system are gripping the film; controlling, while the movable system is moving the predetermined amount in the first direction to the first position, the seal system of the movable system to seal the film; controlling, after the film is sealed by the seal system, a cutting device of the movable system to cut the film; and controlling, after the movable system reaches the first position and the film is sealed by the seal system, the gripper system and the seal system to ungrip the film such that a portion of the film, defined by the cut, moves away from a remainder of the film, wherein the movable system is configured to receive the film therethrough, the gripper system includes at least one body that is configured to grip the film, the seal system includes a seal bar that is configured to heat seal opposite side faces of the film together so as to form a first end of the bag, and the cutting device includes an actuator and a knife, the actuator configured to cause the knife to separate the bag from the remainder of the film by cutting the film.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features, the nature, and various advantages of the disclosed subject matter will be more apparent from the following detailed description and the accompanying drawings in which:

FIG. 1 illustrates a front view of a bagger of an embodiment.

FIG. 2 illustrates a side view of the bagger of the embodiment illustrated in FIG. 1, in which a portion of a tube stock film is unrolled.

FIG. 3 illustrates a front view of a bagger of an embodiment.

FIG. 4 illustrates a perspective view of a rail, and a pulley system associated therewith, of an embodiment.

FIG. 5 illustrates a front view of the rail, and the pulley system associated therewith, of the embodiment illustrated in FIG. 4.

FIG. 6 illustrates a side view of the rail, and the pulley system associated therewith, of the embodiment illustrated in FIG. 4.

FIG. 7 illustrates a rear view of the rail, and the pulley system associated therewith, of the embodiment illustrated in FIG. 4.

FIG. 8 illustrates a perspective view of a component of the pulley system.

FIG. 9 illustrates a side view of the component of the pulley system.

FIG. 10 illustrates a first stage of a process performed by a bagger of an embodiment.

FIG. 11 illustrates a second stage of the process performed by a bagger of an embodiment.

FIG. 12 illustrates a third stage of the process performed by a bagger of an embodiment.

FIG. 13 illustrates a fourth stage of the process performed by a bagger of an embodiment.

FIG. 14 illustrates a fifth stage of the process performed by a bagger of an embodiment.

FIG. 15 illustrates a sixth stage of the process performed by a bagger of an embodiment.

FIG. 16 illustrates a perspective view of a 3D model of the bagger illustrated in FIG. 1.

FIG. 17 illustrates a perspective view of a bagger of an embodiment.

FIG. 18 illustrates a side view of the bagger of the embodiment illustrated in FIG. 17.

FIG. 19 illustrates a front view of the bagger of the embodiment illustrated in FIG. 17.

FIG. 20 illustrates a magnified, perspective view of the bagger of the embodiment illustrated in FIG. 17, wherein a housing is omitted.

FIG. 21 illustrates a magnified, front view of the bagger of the embodiment illustrated in FIG. 17, wherein the housing is omitted.

FIG. 22 illustrates a magnified, side view of the bagger of the embodiment illustrated in FIG. 17, wherein the housing is omitted.

FIG. 23 is a diagram that illustrates a bagger system, including some aspects of a bagger, according to embodiments of the present disclosure.

DETAILED DESCRIPTION

Non-limiting example embodiments of the present disclosure are described below with reference to the accompanying drawings. Similar components in the drawings will be referred to with similar reference numerals, and repeated descriptions thereof may be omitted for clarity.

With reference to FIGS. 1-3 and 16-22, baggers of the present disclosure are described. FIG. 1 illustrates a front view of a bagger 100 of an embodiment. FIG. 2 illustrates a side view of the bagger 100 of the embodiment illustrated in FIG. 1, in which a portion of a tube stock film is unrolled. FIG. 3 illustrates a front view of a bagger 100A of an embodiment, of which aspects described with reference to the bagger 100 may be incorporated, or from which aspects may be incorporated into the bagger 100. FIG. 16 illustrates a perspective view of a 3D model of the bagger 100 illustrated in FIG. 1. FIG. 17 illustrates a perspective view of a bagger 100B of an embodiment, of which aspects described with reference to the bagger 100 may be incorporated, or from which aspects may be incorporated into the bagger 100. FIG. 18 illustrates a side view of the bagger 100B of the embodiment illustrated in FIG. 17. FIG. 19 illustrates a front view of the bagger 100B. FIG. 20 illustrates a magnified, perspective view of the bagger 100B, wherein a housing 205 is omitted. FIG. 21 illustrates a magnified, front view of the bagger 100B, wherein the housing 205 is omitted. FIG. 22 illustrates a magnified, side view of the bagger 100B, wherein the housing 205 is omitted.

According to an embodiment, a bagger 100 may comprise a support frame 110, one or more rollers 120, one or more motors 130, a movable gripper system 140, a seal system 150, a print head bracket 160, a cutter 170, and a bag chute 180.

The support frame 110 may support components of the bagger 100, such as but not limited to the one or more rollers 120, the one or more motors 130, the movable gripper system 140, the seal system 150, the print head bracket 160, the cutter 170, a tension knob 122, and the bag chute 180. The support frame 110 may include, for example, two rails 111 that are configured to movably support opposite ends of a movable portion of the bagger 100 such that the movable portion may move along extending directions of the rails 111 (e.g. upward and downward). Each of the two rails 111 may be, for example, an extruded frame part of the support frame 110 for holding a respective actuator 112 among actuators (e.g. two actuators). The extruded frame part may be for mounting and option adjustment through the use of T slot nuts and bolts.

In an embodiment, the movable portion may be linearly actuated by two actuators 112 that cause the movable portion to move vertically along the rails. The two actuators 112 may be linearly actuators or any other type of actuator that may cause linear movement of the movable portion. The two actuators 112 may be joined together mechanically. In an embodiment, the actuators 112 may each be provided with a respective one of the rails 111. The actuators 112 may be driven by one or more motors 130. In an embodiment, the actuators 112 are each driven by a respective mechanical shaft with a respective gearbox and servo motor. In an embodiment, the actuators 112 are pulley systems 300 with respective belts 310 that are rotated by the respective motors 130, so as to cause linear movement of the movable portion of the bagger 100. An example of the pulley system 300 provided with a rail 111 is illustrated in FIGS. 4-7. As illustrated in FIGS. 4-7, the pulley system 300 may include a belt 310 that is provided in a first component 320 and a second component 330 at separate ends. The first component 320 and the second component 330 may each include a wheel in which the belt 310 may move along. The wheel of the first component 320 and/or the wheel of the second component 330 may act as a drive wheel. For example, the wheel of the component on the bottom side of the bagger 100 (e.g. the first component 320) may be a drive wheel. The drive wheel may be connected to the mechanical shaft which may be connected to the gearbox and servomotor which are configured to drive the belt 310 via the drive wheel. FIGS. 8-9 illustrate an example of the first component 320. As illustrated in FIGS. 8-9, the first component 320 may have a body 321 including slots 322 in which the belt 310 may enter and exit the body 321, and the body 321 may further include the wheel 324 that may be a drive wheel. The drive wheel may be connected to the mechanical shaft 325 which may be driven by a motor 130. The second component 330 may have a similar configuration to the first component 320.

In embodiments, the movable portion may include the movable gripper system 140. In an embodiment, the movable portion may include one or more belt drive mounts 340 that are held by the rails 111 and configured to be moved by the actuators 112 associated with the rails 111. An example of the belt drive mount 340 is illustrated in FIGS. 4-7. The belt drive mount 340 may hold the movable gripper system 140 (and/or other components) such that the movable gripper system 140 (and/or the other components) is configured to be moved by the actuators 112 associated with the rails 111.

The one or more rollers 120 may be provided with a tube stock film 10, and the baggers of the present disclosure may be configured to form and cut bags from the tube stock film 10. In an embodiment, the tube stock film 10 may be, for example, plastic. In an embodiment, the tube stock film 10 may be in the form of a tube, wherein lateral sides of the tube stock film are pre-joined before being provided on a roller 120 so as to only be open in an axial direction of the film. Accordingly, the tube stock film 10 may be wound on a roller 120 in a state in which only one side of the tube stock film 10 may need to be sealed and another side may need to be cut to form a bag. In an embodiment, the one or more rollers 120 may include a roller 120 in which a roll of the tube stock film 10 is mounted, and the roller 120 may rotate to enable the tube stock film 10 to unroll from the roll. As illustrated in FIGS. 1-3, the roller 120 may be mounted to a top of the support frame 110 so as to be at a top of the bagger 100. Alternatively, a roller 120 holding the tube stock film 10 may be provided at a backside of the bagger 100. As illustrated in FIGS. 1-2, the roller 120 may be provided with a tension knob 122, and the tension knob 122 may be configured to control the resistance of the roller 120 to rolling, thereby controlling a tension of the tube stock film 10 when unrolled from the roll.

The movable gripper system 140 of embodiments of the present disclosure may be configured to grip the tube stock film 10 and move upward and downward with and without the tube stock film 10 being gripped by the movable gripper system 140. In an embodiment, the movable gripper system 140 may include one or more grippers 142 that are each provided with one or more respective pneumatic (e.g. air) actuated cylinders. In an embodiment, the movable gripper system 140 may include a pair of grippers 142 as illustrated in FIGS. 1-2, FIG. 3, or FIG. 7. The grippers 142 may be a pair of plates that open and close on opposite sides of the tube stock film 10 to grip and ungrip the tube stock film 10, respectively. The grippers 142 may be configured to open and close to mechanically grip and un-grip the tube stock film 10 by the one or more pneumatic actuated pneumatic cylinders provided with the grippers 142. Alternatively or additionally, the grippers 142 may be configured to grip (or be assisted in the gripping of) the tube stock film 10 by suction force. In an embodiment, the grippers 142 may be vacuum-aided grippers. For example, the movable gripper system 140 may include one or move vacuum devices (e.g. an air pump) that is configured to apply a suction force on the tube stock film 10, such that the grippers 142 grip the tube stock film 10. In an embodiment, the grippers 142 may grip edges of the tube stock film 10. The movable gripper system 140 may be configured to blow a slight amount of air towards the tube stock film 10 in cases in which gripping and movement of the tube stock film 10 is to be avoided. For example, the one or more vacuum devices may be configured to also blow the air. The one or more vacuum devices may include at least one motor configured to cause the suction force and the blowing of air. In an embodiment, the grippers 142 of the movable gripper system 140 may be configured to grip a part of the tube stock film 10 corresponding to an end of a bag.

With reference to FIGS. 1-3 and 16, the seal system 150 may comprise a seal bar 152 and one or more actuators 153 configured to actuate the seal bar 152 to perform a seal process on the tube stock film 10 to form a bag. For example, the seal bar 152 may be configured to seal the tube stock film 10 along a lateral direction of the tube stock film 10 so as to form a sealed end of the bag. An example of the sealed end 12 is illustrated in FIGS. 3 and 15. In an embodiment, the sealed end 12 may be a top end or a bottom end of the bag. The one or more actuators 153 may be a pneumatic actuator that is, for example, a linear actuator, and the seal bar 152 may be a pneumatic (e.g. air) actuated seal bar. In an embodiment, the seal bar 152 of the seal system 150 may be the bag seal bar described in U.S. Pat. No. 6,862,867, which is incorporated by reference. The seal bar 152 may include at least one thermal element and at least one contact surface that is configured to contact the tube stock film 10 when the seal bar 152 is actuated by the one or more actuators 153 of the seal system 150, thereby causing the at least one thermal element to seal opposite faces of the tube stock film 10 together via heat. With reference to FIG. 3, the seal system 150 may be a part of the movable portion, and move vertically with the movable gripper system 140 when the actuators 112 provided with the rails 111 are actuated. For example, the seal system 150 may be mounted to the movable gripper system 140, along with a cutting device (e.g. a cutter 170 described below), and move with the movable gripper system 140 as one unit. Alternatively, the seal system 150 may be mounted on the support frame 110 so as to be configured to move independently of the movable gripper system 140. In an embodiment, the seal system 150 may be thermally separated from other apparatuses (e.g., cutting device, movable gripper system 140, etc.) for the seal system 150 and the other apparatuses to function properly. In an embodiment, hoses 155 for actuating the one or more actuators 153 (e.g. pneumatic linear actuator(s)) of the seal bar 152 may be provided.

Referring to FIGS. 1-3, a cutter 170 may be provided. The cutter 170 may comprise a knife with a blade that is configured to cut the bag from the tube stock film 10, and the cutter 170 may further comprise one or more actuators 172 (e.g. pneumatic linear actuator(s)) configured to move the knife to cut the bag. The one or more actuators 172 may be a pneumatic (e.g. air) actuator that are, for example, linear actuators, and the knife may be a pneumatic (e.g. air) actuated flying knife. The cutter 170 may be provided as a part of the movable portion of the bagger 100. In an embodiment, hoses 175 for actuating the one or more actuators 172 (e.g. pneumatic linear actuator(s)) of the cutter 170 may be provided.

Referring to FIGS. 17-22, a bagger 100B is described below. The bagger 100B may include, for example, a roller 120B, a printer 160B, a movable system 200, and a static bar 220.

The roller 120B may be provided with the tube stock film 10, and may be positioned at a lower, back side portion of the support frame 110B.

The printer 160B may be positioned at an upper, back side portion of the support frame 110B, and may be configured to receive the tube stock film 10 from the roller 120B, and print on the tube stock film 10.

The movable system 200 may be configured to receive and interact with (e.g. seal, cut, and/or hold) the tube stock film 10, after the tube stock film 10 passes through the printer 160B. The movable system 200 may be linearly actuated by one or more actuators 112B such that the movable system 200 moves vertically along the rails 11B of the support frame 110B. The movable system 200 may include a housing 205 that contains rollers 210, a cutter 170B, grippers 140B, and a seal bar 152B. According to embodiments, the movable system 200 may further include a bracket 215 on which other components (e.g. housing 205, the rollers 210, the cutter 170B, the grippers 140B, and the seal bar 152B) of the movable system 200 are mounted so that the components of the movable system 200 are configured to vertically move together along the rails 11B based on the bracket 215B being linearly actuated by the one or more actuators 112B.

According to embodiments, the movable system 200 may include components in an order of, from uppermost to lowermost, the rollers 210, the grippers 140B, the cutter 170B, and the seal bar 152B.

The rollers 210 may be pneumatic powered rollers and may be configured to keep the tube stock film 10 centered in the movable system 200, in a horizontal direction extending in the front-rear direction of the bagger 100B, as the movable system 200 vertically moves. According to embodiments, the rollers 210 when powered on may enable the movable system 200 to move relative to the tube stock film 10 provided therein. For example, the rollers 210 may prevent the tube stock film 10 from being pushed or pulled while the movable system 200 moves.

The grippers 140B may also be provided above the seal bar 152B, and may be configured to grip the tube stock film 10 at predetermined times.

The cutter 170B may be positioned just over the seal bar 152 such that the movable system 200 may seal the tube stock film 10 with the seal bar 152B and then cut the tube stock film 10 with the cutter 170B, without the movable system 200 moving between two separate positions for sealing and cutting. Accordingly, time may be saved between sealing and cutting operations. The cutter 170B may include, for example, an actuated blade that is configured to transversely cut the tube stock film 10.

According to embodiments, the movable system 200 may further include an air bar that is configured to blow a slight amount of air towards the tube stock film 10 so as to reduce static and keep the tube stock film 10 from contacting other components (e.g. the seal bar 152B and the cutter 170B) of the movable system 200 at predetermined times. According to embodiments, the air bar may be provided between the rollers 210 and the cutter 170B.

The static bar 220 may be located at an upper, front side portion of the support frame 110B. The static bar 220 may be positioned between the movable system 200 and the printer 160B, with respect to a traveling path of the tube stock film 10. The static bar 220 may be configured to contact the tube stock film 10 so as to eliminate or reduce static on a portion of the tube stock film 10 before the portion of the tube stock film 10 enters the movable system 200.

According to embodiments, the tube stock film 10 may be routed from the roller 120B to the printer 160B, to the static bar 220, to the rollers 210, and then to the cutter 170B and the seal bar 152B. The movable system 200 may be configured to be actuated by the actuators 112B so as to vertically move along the rails 11B so as to produce bags of various lengths.

According to embodiments, the bagger 100B may further include a wifi air manifold, human-machine interface touch screen, and a bag presenting apparatus.

Referring to FIG. 23, the bagger 100 (or bagger 100A or bagger 100B) may also include a controller 900 comprising at least one processor 910 with memory 920 including computer program code. The computer program code, when executed by the at least one processor 910, may be configured to cause the controller 900 to control any number of components of the bagger 100 to perform its functions (e.g. moving, gripping, un-gripping, sealing, heating, etc.). For example, the controller 900 may be caused to generate and send a signal(s) to the components that causes the components to be manipulated (e.g. to move, to grip, to start heating, etc.) according to control methods, including those known to persons of ordinary skill in the art, to perform their respective functions.

In embodiments, the bagger 100 may comprise printers that are attached to the support frame 110 using, for example, t slot nuts and mounting brackets. In an embodiment, the bagger 100 may comprise a printer head 162 (e.g. a printer) with, for example, a print head bracket(s) 160. The printer head 162 may be configured to print information on the tube stock film 10 that forms the bags. For example, the printer head 162 may print lot numbers, data codes, product IDs, barcodes, etc. The print head bracket(s) 160 may be attached to the actuators 112 on the rails 111 (e.g. belt driven actuators) by way of t slot nuts in extruded aluminum frames of the rails 111 with actuators 112.

With reference to FIG. 3, baggers (e.g. bagger 100 or bagger 100A) of the present disclosure may include a top holding grip system 240. The top holding grip system 240 may have a configuration similar to the movable gripper system 140, except the top holding grip system 240 may be mounted on the support frame 110 so as be stationary with respect to the vertical direction. For example, the top holding grip system 240 may be non-moveable in the vertical direction.

According to processes of the present disclosure, baggers of the present disclosure may be configured to, after a start button is pressed, make a bag(s) of a programmed length(s) by, for example, closing grippers of the bagger, activating actuators to move the grippers so as to pull the tube stock film to a predetermined length, and sealing the tube stock film to form a bag using the bag seal bar.

According to embodiments, an open end of the bag (e.g. a bottom end) may then be gripped by two vacuum bars 190 (refer to FIG. 17) of the bagger so as to be opened for loading of product automatically, or the bag may be cut and dropped in a bag shoot after cutting. The cutting may be performed by cutters of the present disclosure. The two vacuum bars 190 may be mounted on the support frame 110 of the baggers illustrated in FIGS. 1-3, for example on the rails 111, and be configured to apply a suction force on respective faces of opposite faces of the tube stock film so as to open the open end of the tube stock film 10. The two vacuum bars 190 may be provided with one or move vacuum devices (e.g. an air pump) that is configured to apply a suction force on the tube stock film, such that the vacuum bars 190 grip the tube stock film. The one or more vacuum devices may include a motor configured to cause the suction force. The two vacuum bars 190 may be a part of the movable portion and move vertically with the movable gripper system when the actuators are actuated. Alternatively, the seal system 150 may be mounted on the support frame 110 so as to be stationary, or mounted on the support frame 110 so as to be configured to move independently of the movable gripper system 140. The vacuum bars 190 and the vacuum devices provided therewith may be controlled by the controller 900.

After the first bag is made, a second bag may be sealed by the seal bar 152 of the seal system 150 as the tube stock film 10 is being pulled downward. This saves time and speeds up the processing by the bagger.

In embodiments, the bagger may further comprise printer units, RFID printers, labeling units, etc. In embodiments, a bagger system may be provided that includes any of the baggers of the present disclosure. The bagger system may further comprise a conveyor that is configured to move products to the bagger of the bagger system. The bagger system may further comprise a 3D scanner or others means that may scan product coming down the conveyor to the bagger. Accordingly, information of a size of the product can be obtained by the scanner and the bagger can create a programmed length bag based on the information. In other words, the bagger of the bagger system may be configured to make custom length bags based on the product(s) scanned. Accordingly, bag waste may be reduced and time may be saved.

An example process performable by baggers of the present disclosure is provided below. Some stages of the process are described with reference to FIGS. 10-15.

According to an embodiment, an operator of the bagger may feed the tube stock film 10 into the grippers 142 of the movable gripper system 140, and close guarding of the bagger. The guarding may refer to a guarding enclosure around any number of components of the bagger to prevent an operator from getting injured. The guarding may have to be opened by the operator for the operator to load the tube stock film 10 into the bagger, and when closed, the guarding may prevent the operator from physically interacting with the tube stock film 10 and any number of other components of the bagger so at to avoid injury. With reference to FIG. 10, after a start button of the bagger is pressed, the controller 900 may cause the grippers 142 of the movable gripper system 140 to close so as to grip the tube stock film 10 at a portion 11 of the tube stock film 10 corresponding to, for example, a bottom end of a bag to be formed. With reference to FIG. 11, the controller 900 may then control the grippers 142 to move a predetermined amount in a first direction (e.g. a downward direction) to a first predetermined position A (while gripping portion 11 of the tube stock film), based on a manually inputted length or a length determined based on information from a scanner 950 (refer to FIG. 17) that includes a sensor 922 (e.g. an image scanner that includes an image sensor) and any offsets. For example, the controller 900 may control the motors 130 to move the actuators 112 associated with the rails 111 a specified amount so as to cause the grippers 142 to move to the first predetermined position in the first direction, and the grippers 142 causing a predetermined length of the tube stock film 10 to be available for forming the bag within the bagger. The scanner information may include information about a size of a product to be inserted into the bag. The scanner information may be obtained by the scanner 950 by scanning the product and may be sent to the controller 900 by wired or wireless communication. With reference to FIG. 12, the controller 900 may then cause the grippers 142 to un-grip the tube stock film 10 by opening, and move in a second direction (e.g. an upward direction) to a second predetermined position B. The second predetermined position B may be at or nearby a portion of the tube stock film 10 corresponding to a top end of the bag to be formed. While the grippers 142 are moving in the second direction to the second predetermined position B, the controller 900 may cause the movable gripper system 140 (or another portion of the bagger) to provide a slight amount of air to be blown on a side (e.g. a backside) of the tube stock film 10 to avoid accidental gripping or movement of the tube stock film 10. Once the grippers 142 reach the second predetermined position B, the controller 900 may cause the grippers 142 of the movable gripper system 140 to close so as to grip the tube stock film 10, and further cause the top holding grip system 240 to close so as to also grip the tube stock film 10. In an embodiment, the top holding grip system 240 may close so as to grip the tube stock film 10 any time after the grippers 142 of the movable gripper system 140 reach the first predetermined position A. For example, the top holding grip system 240 may close while the grippers 142 are stationary at the first predetermined position A or moving towards the second predetermined position B. While the top holding grip system 240 and the grippers 142 of the movable gripper system 140 are in the gripped state, the controller 900 may then control the motors 130 to move the grippers 142 of the movable gripper system 140 downward so as to cause the tube stock film 10 to be tensioned between the grippers 142 of the movable gripper system 140 and the top holding grip system 240. With reference to FIG. 13, while portion 14 the tube stock film 10 is tensioned, the controller 900 may control the seal system 150 (that includes the seal bar 152) to be operated for a set amount of time and pressure to seal the top end of the bag. For example, the controller 900 may control the one or more actuators 153 of the seal system 150 to actuate the seal bar 152 into a contact state with the tube stock film 10, and heat the tube stock film 10 with the seal bar 152 to cause the tube stock film 10 to be sealed at a portion corresponding to a top end of the bag. For example, the sealed portion may be the sealed end 12 shown in FIGS. 3 and 15. With reference to FIG. 14, the controller 900 may cause the one or more actuators 153 of the seal system 150 to actuate the seal bar 152 so as to separate from the tube stock film 10 when a set heating time passes so as to finish the seal process. During and/or after the seal process, the controller 900 may control the grippers 142 of the movable gripper system 140 to grip a portion of the top end of the bag for presentation (e.g. tensioning the top end of the bag), and control the knife of the cutter 170 to actuate to cut the top end of the bag from the remainder of the tube stock film 10, so as to separate the bag from the tube stock film 10. In an embodiment, the top holding grip system 240 may be controlled to grip or maintain grip of a portion of the tube stock film 10, above the top end of the bag, such that the top end of the bag is tensioned between the top holding grip system 240 and the movable gripper system 140 for the cutting. In an embodiment, the movable gripper system 140 may be controlled to un-grip the bag after the cutting, while the top holding grip system 240 maintains grip of the portion of the tube stock film 10 above the bag, such that the bag is enabled to fall away due to the cutting.

On the second and following cycles for forming bags, the controller 900 may control the bagger to seal subsequent bags while the tube stock film 10 is pulled to length by the movable gripper system 140 gripping and downwardly moving the tube stock film. Accordingly, time may be saved. The process may be repeated.

In an embodiment, during a first cycle for forming a bag, the bagger may pull an open section of the tube stock film 10 (e.g. a bottom of the bag to be formed) to a bottom position, then release the grippers 142 of the movable gripper system 140, move to the sealing position (e.g. a position corresponding to a top end of the bag to be formed), then perform the sealing and cutting operations. In an embodiment, an accurate first bag length and/or positions of the tube stock film 10 (e.g. a position of the unrolled tube stock film) may be identified and stored in memory of the bagger based on the first cycle.

In an embodiment, after the first cycle, the bagger may be configured to move directly to the sealing and cutting position of a second bag (e.g. a top end of the second bag), based on an identified position of the tube stock film 10 from the first cycle. Accordingly, the bagger may be configured to move directly to the sealing and cutting position and perform these operations while the movable gripper system 140 pulls the tube stock film downward to form the second bag of a correct length.

According to an embodiment with reference to FIG. 15 (which shows the first bag still attached for demonstration or other purposes), after the first bag is cut and the movable gripper system 140 releases the first bag, the second cycle may include moving the movable gripper system 140 to a position corresponding to an intended bag length (e.g. a top end of the second bag) and then closing the movable gripper system 140. Following, the top holding grip system 240 may be controlled to un-grip the tube stock film 10, and the movable gripper system 140 may be controlled to move downward while gripping the tube stock film 10 such that the tube stock film 10 is pulled downwards. During such downward movement while the movable gripper system 140 is in a closed state, the seal bar 152 may be controlled to seal the tube stock film 10 to form an end (e.g. a top end) of a second bag. Based on the movable portion of the bagger and/or the tube stock film 10 reaching a predetermined position (e.g. a position stored in the memory of the bagger), the bagger may control the top holding grip system 240 to grip the tube stock film 10 while the tube stock film 10 is continued to be pulled downed by the movable gripper system 140. Accordingly, the tube stock film 10 may be tensioned. While the tube stock film 10 is tensioned, the bagger may control the cutter 170 to cut the tube stock film 10, and the movable gripper system 140 to un-grip the second bag such that the second bag falls away from the remainder of the tube stock film 10. In an embodiment, the process of the second cycle may then be repeated to perform subsequent cycles. In an embodiment, the controller 900 of the bagger may be configured to control the bagger to perform the cycles.

An example process performable by the bagger 100B of the present disclosure is provided below.

Based on the bagger 100B being turned on and all machine safeties having been met (e.g. determined to be met by the controller 900), the controller 900 may control the movable system 200 to move upwards to a home position, which the controller 900 may set to have a value of 0. The controller 900 may then control the movable system 200 to move downward to a first position, based on a predetermined bag length, to wait for the tube stock film 10 to be loaded into the rollers 210. After the tube stock film 10 is loaded into the rollers 210, through the grippers 140B, and through the seal bar 152B by an operator, and a start input (e.g. caused by an operator pressing a start button of the bagger 100B) is received by the controller 900, the controller 900 may then begin a bag forming process. The bag forming process may include the following steps:

First, the controller 900 may control the rollers 210 to be turned on, by controlling an air motor(s) of the rollers 210, and the controller 900 may control the movable system 200 to move upwards to a second position, based on the predetermined bag length, while the rollers 210 are on. At such time, the grippers 140B and the seal bar 152B are in non-gripping states with respect to the tube stock film 10, and the movable system 200 moves relative to the tube stock film 10. After the movable system is determined to have reached the second position by the controller 900 (e.g. based on a sensor reading), the controller 900 may control the rollers 210 to be turned off, and control the grippers 140B and the seal bar 152B to close on the tube stock film 10 so as to both be in a gripping state with respect to the tube stock film 10. While the grippers 140B and the seal bar 152B are in the gripping state, the controller 900 may control the movable system 200 to move downwards to a third position such that a bottom of the tube stock film 10 is pulled downwards to, for example, a presenter. While the movable system 200 is moving downwards, the controller 900 may control the seal bar 152B to seal a portion of the tube stock film 10 that corresponds to a bottom of a bag, and then the controller 900 may control the cutter 170B to transversely cut the tube stock film 10 immediately above where the seal was provided. After the movable system 200 is determined to have reached the third position by the controller 900 (e.g. based on a sensor reading), the controller 900 may control the grippers 140B and the seal bar 152B to open so as to return to the non-gripping state with respect to the tube stock film 10. Accordingly, the bag formed from the tube stock film 10 may fall away from a remainder of the tube stock film 10 and be received by the presenter, and the bag forming process may be completed.

, The controller 900 may subsequently control the bagger 100B to repeat the bag forming process any number of times. For example, while the movable system 200 is at the third position, the controller 900 may again control the rollers 210 to be turned on, and may control the movable system 200 to move upwards to the second position, based on the predetermined bag length. Thereafter, the subsequent bag forming process may continue.

According to embodiments, the home position and the second position may be the same position as each other or different positions, and/or the first position and the third position may be the same position as each other or different positions.

According to embodiments, the controller 900 may be configured to control the baggers of the present disclosure in various modes. For example, controller 900 may control the baggers of the present disclosure in a “manual mode” in which operation of the bagger begins based on an operator pressing a start button of the bagger or inserting a start key into the bagger. The controller 900 may also control the baggers of the present disclosure in a “box mode” in which the bagger is controlled to continuously make bags of a predetermined length that is set using a human-machine interface of the bagger. The bagger may continuously make the bags until a stop input is received by the controller 900 (e.g., pressing a stop cycle button of the bagger). The controller 900 may also control the baggers of the present disclosure in an “automatic mode” in which the controller 900 automatically controls the bagger to make bags of a certain length based on receiving an input identifying the length. For example, the input identifying the length may be received from a scanner that scans a size of contents to be inserted into the bags to be made.

It should be noted that although a few embodiments have been described, those skilled in the art will readily appreciate that many modifications are possible to the embodiments without materially departing from the novel teachings and advantages of the embodiments. Accordingly, all such modifications are intended to be included within the scope of the embodiments. Therefore, it is to be understood that the foregoing is illustrative of various embodiments and is not to be construed as limited to the specific embodiments illustrated.

Claims

1. A bagger comprising: a support frame comprising two rails;a movable system configured to receive a film therethrough, the movable system comprising a seal system, a gripper system, and a cutting device, the movable system attached to the two rails of the support frame;actuators including a first actuator and a second actuator, the first actuator and the second actuator each configured to move the movable system along a respective rail of the two rails of the support frame, simultaneously; anda roller configured to hold a roll of the film, the roller connected to a portion of the support frame, whereinwherein the gripper system comprises at least one body that is configured to grip the film,the seal system comprises a seal bar that is configured to heat seal opposite side faces of the film together so as to form a first end of a bag, andthe cutting device comprises an actuator and a knife, the actuator configured to cause the knife to separate the bag from another portion of the film by cutting the film.

2. The bagger of claim 1, wherein the movable system further comprises a pneumatic roller that is configured to contact the film.

3. The bagger of claim 1, further comprising a static bar above the movable system, the static bar configured to reduce static on a portion of the film before the portion of the film enters the movable system.

4. The bagger of claim 3, wherein the movable system further comprises a housing that comprises the seal system, the gripper system, and the cutting device, the housing attached to the two rails of the support frame.

5. The bagger of claim 1, wherein the cutting device is configured to transversely cut the film at a position that is between the seal system and the gripper system.

6. The bagger of claim 1, further comprising: a controller comprising at least one processor and memory, the controller configured to: control the movable system to move a predetermined amount along the two rails in a first direction to a first position while the gripper system and the seal system of the movable system are gripping the film;control, while the movable system is moving the predetermined amount in the first direction to the first position, the seal system of the movable system to seal the film;control, after the film is sealed by the seal system, the cutting device to cut the film; andcontrol, after the movable system reaches the first position and the film is sealed by the seal system, the gripper system and the seal system to ungrip the film such that a portion of the film, defined by the cut, moves away from a remainder of the film.

7. The bagger of claim 6, wherein the movable system further comprises a pneumatic roller that is configured to contact the film, and the controller is further configured to control, before the movable system is controlled to move in the first direction to the first position, the movable system to move a predetermined amount along the two rails in a second direction to a second position while the gripper system and the seal system of the movable system are not gripping the film and the pneumatic roller is operated.

8. The bagger of claim 7, wherein the controller is configured to control the pneumatic roller to not be operated while the movable system is controlled to move in the first direction to the first position.

9. The bagger of claim 8, wherein the movable system comprises a housing that comprises the seal system, the gripper system, the pneumatic roller, and the cutting device, the housing attached to the two rails of the support frame.

10. The bagger of claim 9, wherein the cutting device is configured to transversely cut the film at a position that is between the seal system and the gripper system.

11. A method of forming a bag from a film by using a bagger, the method comprising: controlling a movable system of the bagger to move a predetermined amount in a first direction to a first position while a gripper system of the movable system and a seal system of the movable system are gripping the film;controlling, while the movable system is moving the predetermined amount in the first direction to the first position, the seal system of the movable system to seal the film;controlling, after the film is sealed by the seal system, a cutting device of the movable system to cut the film; andcontrolling, after the movable system reaches the first position and the film is sealed by the seal system, the gripper system and the seal system to ungrip the film such that a portion of the film, defined by the cut, moves away from a remainder of the film,wherein the movable system is configured to receive the film therethrough, the gripper system includes at least one body that is configured to grip the film, the seal system includes a seal bar that is configured to heat seal opposite side faces of the film together so as to form a first end of the bag, and the cutting device includes an actuator and a knife, the actuator configured to cause the knife to separate the bag from the remainder of the film by cutting the film.

12. The method of claim 11, wherein the movable system further includes a pneumatic roller that is configured to contact the film.

13. The method of claim 11, wherein the movable system is configured to move along rails of the bagger.

14. The method of claim 11, further comprising: controlling, before the movable system is controlled to move in the first direction to the first position, the movable system to move a predetermined amount in a second direction to a second position while the gripper system and the seal system of the movable system are not gripping the film and a pneumatic roller of the movable system is operated.

15. The method of claim 11, wherein the bagger further includes a static bar above the movable system, the static bar configured to reduce static on a portion of the film before the portion of the film enters the movable system.

16. The method of claim 11, wherein the movable system further includes a housing that includes the seal system, the gripper system, and the cutting device.

17. The method of claim 11, wherein the cutting device is configured to transversely cut the film at a position that is between the seal system and the gripper system.

18. The method of claim 14, wherein the controlling the movable system to move in the first direction to the first position comprises controlling the movable system to move in the first direction to the first position while the pneumatic roller is not operated.

19. The method of claim 14, wherein the movable system further includes a housing that includes the seal system, the gripper system, the pneumatic roller, and the cutting device.

20. The method of claim 19, wherein the housing is configured to move along rails of the bagger.