1. Technical Field
The present disclosure relates to apparatus for wrapping loads with packaging material, and more particularly to apparatus for wrapping plastic film around product on a pallet.
2. Background
Various packaging techniques have been used to assemble a load of unit products and subsequently wrap them for transportation, storage, containment and stabilization, protection and waterproofing. Products are often stacked as a load on a pallet to simplify handling of the products. The pallet load is commonly wrapped with stretch wrap packaging material. One system uses stretch wrapping machines to stretch, dispense, and wrap stretch packaging material around a load. Stretch wrapping can be performed as an inline, automated packaging technique that dispenses and wraps packaging material in a stretched condition around a load on a pallet to cover and contain the load. Pallet stretch wrapping, whether accomplished by a turntable, a rotating arm, or a vertical rotating ring, typically covers the four vertical sides of the load with a stretchable film, such as polyethylene film. In each of these arrangements, relative rotation is provided between the load and the packaging material dispenser to wrap packaging material around the sides of the load.
A turntable type pallet stretch wrapping machine includes a frame, a pulley or hub rotatably mounted to the frame, a turntable mounted on the hub, a vertically movably film dispensing assembly, and a drive mechanism for rotating the hub. The frame includes rollers that rotatably support the underneath surface of the turntable for rotation relative to the film dispensing assembly. A loaded pallet that is to be wrapped with film is placed on the turntable. The loaded pallet is rotated about a generally vertical axis by rotating the turntable with the drive mechanism. The loaded pallet is progressively wrapped circumferentially and vertically, i.e. spirally, by film supplied from a vertically movable roll of film of the film dispensing assembly.
A loaded pallet is typically placed upon the turntable with a forklift or pallet jack. If the loaded pallet is not raised to a sufficient height by the operator of the forklift or pallet jack as the loaded pallet is being positioned over the turntable, the edge of the pallet can strike the edge of the turntable, which can cause plastic deformation, i.e. permanent bending, of the shaft that rotatably mounts the hub to the frame, thus requiring repair. The edge of the turntable can also be struck by other objects or machines encountered in a typical warehouse environment that could cause permanent bending of the shaft. For example, the edge of the turntable could be struck by the tines of a fork truck or pallet jack, the mast of a fork truck, or even by an unpalletized load itself.
Another difficulty associated with placing the loaded pallet upon the turntable is accurately placing the pallet in the center of the turntable. If the loaded pallet is placed on the turntable offset from the rotational axis of the turntable, the weight of the loaded pallet will not be evenly supported by the turntable rollers. Even if the loaded pallet is placed in the center of the turntable, if the load is not evenly distributed on the pallet the same situation can occur. And, even if the loaded pallet is placed in the center of the turntable, and even if the load is evenly distributed on the pallet, the weight of the loaded pallet might still not be evenly supported by the turntable rollers, due to manufacturing tolerances in the production of the frame, turntable, pulley/hub, etc., or due to the effects of the weight distribution of the load in combination with the dynamics of the turntable. All of these scenarios can cause increased wear on the rollers and increased vibration during rotation of the turntable.
Accordingly, a need therefore exists for a stretch wrapping machine turntable assembly that overcomes the drawbacks of conventional stretch wrapping machine turntable assemblies such as those described above.
The present invention overcomes the foregoing and other shortcomings and drawbacks of conventional turntable assemblies used in stretch wrapping machines. While the invention will be described in connection with certain embodiments, it will be understood that the invention is not limited to these embodiments. On the contrary, the invention includes all alternatives, modifications, and equivalents as may be included within the spirit and scope of the present invention.
According to one aspect of the present invention, a turntable assembly for a stretch wrapping machine comprises a frame, a turntable mounted to the frame for rotation about a generally vertical turntable axis of rotation, and a plurality of rollers rotatably mounted to the frame and defining a generally horizontal supporting plane for supporting the turntable. Each of the plurality of rollers has an axis of rotation generally parallel to the supporting plane and generally passing through the turntable axis of rotation. The frame is constructed of a material and of a geometry so as to elastically deform, upon a load being placed upon the turntable that results in the load not being evenly supported by the rollers, to permit the axis of rotation of at least one roller of the plurality of rollers to tilt relative to the horizontal supporting plane while still passing through the turntable axis of rotation.
The plurality of rollers can comprise a plurality of pairs of rollers, each pair of rollers of the plurality of pairs of rollers being mounted on a respective frame member of the frame such that one roller of the pair of rollers is positioned on one side of the frame member and the other roller of the pair of rollers is positioned on the other side of the frame member. In one embodiment, each frame member can be constructed such that the deflection under load conditions will not exceed the yield strength of the material of the frame member. Each frame member can be constructed of a material and of a geometry so as to elastically deform an amount sufficient to permit the roller pair axis of rotation to tilt about 3 degrees when a load of about 3,500 pounds is placed on one roller of the pair of rollers. For example, each frame member can be generally rectangular in cross section having a height of about 2.0 inches and a width of about 0.25 inches, and can be fabricated of A36 steel. The pair of rollers can be positioned generally midway along a length of the frame member. The frame member can have a reduced height between the pair of rollers and each end of the frame member if desired. Alternatively the pair of rollers can be positioned near one end of the frame member, and the frame member can have a reduced height at the end near which the pair of rollers is positioned.
In another aspect of the present invention, a turntable assembly for a stretch wrapping machine comprises a frame, a hub rotatably mounted to the frame on a shaft, and a turntable mounted to the hub for rotation about a generally vertical turntable axis of rotation. The frame includes hub deflection limiting structure spaced around the turntable axis of rotation at about 0 degrees, at about 90 degrees, and at about 180 degrees. The deflection limiting structure is spaced from the hub by an amount such that if the turntable is struck causing the hub to bend the shaft, the shaft will elastically deform rather than plastically deform.
The frame of the turntable assembly can comprise a generally circular outer frame member, a pair of generally longitudinally oriented frame members connected to the outer frame member, one of the pair of longitudinally oriented frame members being located on one side of the hub and the other of the pair of longitudinally oriented frame members being located on the other side of the hub, and a generally transversely oriented frame member connected to the pair of generally longitudinally oriented frame members. For example, each of the pair of generally longitudinally oriented frame members can be spaced from an outer edge of the hub by about 3/32 inches, and the generally transversely oriented frame member can be spaced from an outer edge of the hub by about 3/32 inches.
The above and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and the description thereof.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the general description of the invention given above, and the detailed description given below, serve to explain the principles of the invention.
Reference will now be made to the present embodiments of the disclosure, examples of which are illustrated in the accompanying figures. Wherever possible, the same reference numbers will be used throughout the figures to refer to the same or like parts.
As shown in
Relative rotation between packaging material dispenser 12 and load 16 may be provided by a turntable assembly 100, shown in
A belt 112 operatively couples pulley 104 and a drive mechanism 114. Belt 112 is in tension, and engages portions of pulley 104 and drive mechanism 114. The drive mechanism 114 may include, for example, a motor 105 configured to engage and drive belt 112. Belt 112, pulley 104, and the drive mechanism 114 may form a drive assembly. When belt 112 is driven, belt 112 causes rotation of pulley 104, turntable 102, and load 16. Drive elements other than belts and pulleys may be used.
Referring to
Referring to
The first, second, third, and fourth pairs of frame members 160, 160; 162, 162; 164, 164; and 166, 166 support the rollers 110. Each roller 110 preferably includes first and second rollers such as roller bearings 110a, 110b located on opposite sides of a respective frame member and spaced from each other (centerline-to-centerline) by about 2.76 inches. Referring to
As mentioned above, the desired stiffness or spring rate of the roller supporting frame members or beams can be obtained through the selection of a number of variables, such as the material of the frame members, the cross-section of the frame members, the length of the frame members, the position of the rollers along the frame members, the “end conditions” of the frame members, i.e. how the ends of the frame members are attached to adjacent structure (welding generally makes for a stiffer connection and hence a stiffer frame member, whereas bolting/screwing generally makes for a less stiff connection and hence a less stiff frame member, whereas pinning/riveting generally makes for an even less stiff connection and hence an even less stiff frame member, for example), and the like. One example of such a combination of variables that produces an acceptable stiffness or spring rate is to fabricate the frame members or beams from A36 steel with a rectangular cross-section having a height of about 2 inches and a width of about 0.25 inches, in combination with the following lengths and end conditions of the frame members or beams.
Referring to
Referring to
Referring to
The above-described roller supporting frame member materials, frame member cross-sectional shapes and dimensions, frame member lengths, positions of the rollers along the lengths of the frame members, and frame member end conditions are merely illustrative and exemplary; other materials, shapes, dimensions, lengths, roller positions, and end conditions can also be used to produce acceptable stiffnesses/spring rates. It is believed that the above-described materials, shapes, dimensions, lengths, roller positions, and end conditions produce about a 3 degree angle of tilt a if a 3,500 pound point load is placed at the centerline of one of the rollers 110a, 110b, as shown in
As mentioned above, frame 122 of turntable assembly 120 includes a pair of generally longitudinally oriented frame members or beams 124, 124 connected to the outer frame member 122, and a generally transversely oriented frame member or beam 126 connected to the pair of generally longitudinally oriented frame members 124, 124. Hub or pulley 104 is rotatably mounted to base plate 130 of frame 122 via shaft 132. As shown in
The above distances X and Y are a function of, among other things, the yield strength of the material from which the shaft 132 and/or spacer 135 are fabricated. For example, bolt 132 was chosen to be an M12 class 10.9 hex head bolt, and spacer 135 was chosen to be a length of 1018 cold-rolled hex head rod, the lower end of which is non-rotatably mounted in a mating hex hole in base plate 130. In addition, base plate 130 was chosen to be fabricated of A36 steel having a length of about 18 inches, a width of about 8 inches, and a thickness of about 0.25 inches, and backer bar 131 was chosen to be fabricated of A36 steel having a length of about 12 inches, a width of about 2 inches, and a thickness of about 0.5 inches. These materials, shapes, sizes, etc., and distances X and Y, are merely illustrative and exemplary; other materials, shapes, sizes, etc., and distances X and Y can also be used to produce acceptable results.
While the present invention has been illustrated by the description of one or more embodiments thereof, and while the embodiments have been described in considerable detail, they are not intended to restrict or in any way limit the scope of the appended claims to such detail. For example, while roller pairs have been shown and described, the invention could as well be practiced with single rollers cantilevered from their supporting structure. The various features shown and discussed herein may be used alone or in combination. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of Applicants' general inventive concept.
This application claims priority to U.S. Provisional Application Ser. No. 61/644,000 filed May 8, 2012 (pending), the disclosure of which is incorporated by reference herein in its entirety.
Number | Date | Country | |
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61644000 | May 2012 | US |