CA2180097A1 - Wrapping machine and method - Google Patents

Abstract

A machine and method for wrapping cylindrical workpieces such as rolls of bathroom tissue and paper towel. The machine includes a workpiece infeed conveyor, a wrapping paper feeder, a rotating carousel having a plurality of pockets, and a discharge conveyor. A piece of wrapping paper supplied by the paper feeder is perforated and burst into a single sheet. The sheet and a workpiece are directed into a pocket in the rotating carousel whereby the sheet is banded around the periphery of the workpiece by a clamping plate, underfolder plate, and brush. Next a pair of stuffer spindles driven by a barrel cam and a pair of rotating star wheels whose compound motion is derived from geneva wheels fold and tuck the wrapping paper around the parallel sides and into the center tube of each workpiece. The wrapped workpieces are ejected from the rotating carousel onto a discharge conveyor. The method of wrapping is also disclosed.

Description

~, ~180oq7 g Machine and Method Field of Invention 5 The present inYention relates to the field of r~rk~ein~ machines for r~rk~ein~workpieces. Specifically, the present invention relates to the p~rk~ein~ of workpieces made from paper, like bathroom tissue and paper towels.
Background of the Invention In the past packaging or wrapping machines for cylindrical workpieces, such as rolls of bathroom tissue and paper towels, have suffered many drawbacks. For example, some packaging machines have not been able to package the bathroom tissues rolls or paper towel rolls as fast as these products are m~nllf~rt~lred. This 1 5 is especially true when only a small number of rolls are packaged together or when each roll is wrapped separately.
A holding area or ~ccllmlll~tr,r is typically established between the paper winder that forms the rolls and the wrapping machine to hold the overflow of rolls or 20 wulkl~iec~ waiting to be wrapped. The ~rCllmlll~tor is used for two primary reasons. First, if the wrapping machine malfunctions or must be shut down for repair, the winder can continue to wind paper rolls from the parent or material 21 800~7 roll and does not have to be shut down. The wound rolls are stored in the n~c..m.-l~tor until the wrapping machine i8 running again. Second, when it is necessary to install a new parent roll in the winder, the winder is typically run faster before it is shut down. This quickly fills the accumulator with wound rolls 5 and the wrapping machine can continue to operate and wrap the paper rolls stored in the accumulator while the parent roll is changed. A parent roll changetakes approximately 0 minutes. The goal is to change the parent roll, restart the winder and begin producing wound paper rolls again before the wrapper has wrapped all of the rolls in the accumulator. If the goal is achieved, the wrapping 10 machine does not have to be shut down each time the parent roll is changed.
Additionally, many prior art wrapping machines utilize glue. For example, prior art single roll wrapping machines often require that glue be applied on either the wrapping paper or on the wound roll so that the leading edge of the wrapping 15 paper can be a&ered to the wound roll. The wound roll is then rotated to drawthe wrapping paper around the outer periphery of the roll. Besides adding extra expense to the machine and the wrapped product, glue is typically messy and can easily clog in the wrapping machine.
20 Prior art wrapping machines also suffer from a not insllh~stq~t;~l amount of down time and a fairly high scrap rate. Scrap rate is commonly defined as the amount of product which is not suitably wrapped and therefore cannot be sold. Scrap must be either l~wl~p~ed or disposed of. While some prior art machines are capable of wrapping at sllhst~nt~ y the same rate as our wrapping machine, 2 5 they are less reliable. An unreliable machine can produce many scrap pieces before the wrapping machine can be stopped and the problem fixed. If the wrapping machine is down for a period of time greater than the time it takes forthe winder to fill the a~ m~ tor, the winder must be shut down as well.
5 Additionally, even if the prior art machines are filnction;n~ normally and/or operating at a rate of production equal to our wrapping machine they will still have a scrap rate that is higher than the scrap rate of our invention.
In the industry, the reliability of a wrapping machine is typically judged by the 10 number of rolls wrapped per day, excluding scrap. Our invention comprises a wrapping machine for wrapping rolls of bathroom tissue or paper towels that can wrap the product at a much faster rate when compared with prior art machines having the same reliability. Our machine is highly reliable and has a very low scrap rate. Unlike known high rate m~(hinec, our wrapping machines does not 15 require any glue to perform the wrapping process.
A major difference between our wrapping machine and some prior art wrapping machines is that in our machine the wound paper roll is not rotated. Our wrapper utilizes a rotating carousel having a plurality of pockets. The wrapping2 0 paper and wound roll or workpiece are sequentially fed into each pocket as the carousel rotates and the wrapping process occurs as the carousel makes one complete revolution. A fully wrapped workpiece is ejected near the end of the revolution and another piece of wrapping paper and workpiece are inserted. The workpieces are not rotated, relative to the carousel, when wrapped; only the 25 carousel is rotated.

2 i ~0097 It is an object of our invention to provide a wrapping machine that wraps cylindrical workpieces reliably at a high rate of speed with little or no scrap produced. It is an object of our invention to provide such a wrapping machine S that utilizes clamping and underfolding devices to snugly wind and hold the wrapping paper against the workpiece while it is wrapped. It is a further object to provide such a wrapping machine that utilizes a pair of geneva wheel driven starwheels along the outer edges of each pocket and a pair of stuffer spindles to neatly and securely fold the wrapping paper over the outer parallel sides of the 1 0 workpiece and tuck the wrapping paper into the ~vorkpiece center tube. It isanother object of our invention to apply the wrapper around the workpiece in a neat and secure fashion such that the wrapper fits snugly about the workpiece and there are no gaps between the wrapper and the workpiece. It is yet another object of our invention to provide a wrapping machine that is compact, can be 1 5 easily moved, and is flexible with respect to the location of its infeed and e~it conveyors.
These and other objects of our invention will become apparent in the descriptions that follow. We know of no prior art that teaches or discloses our invention.

Summary of the Invention Our invention comprises a wrapping machine for wrapping rolls of bathroom 2 5 tissue, paper towels, and the like or equivalent. These products will be referred to `
herein as workpieces. Each workpiece has a cylindrical shape, an arcuate or curved outer surface, a pair of sllhst~nt~ y circular sllhst~nt;~lly parallel outer sides or flat sides, and a center tube.
5 Our invention's primary components include a roll infeed conveyor, a wrapping paper feeder, a frame structure, a main motor and transmission, a rotating carousel ml~h~nism h~ving a plurality of wrapping stations or pockets, and a discharge assembly. The wrapping paper feeder includes a wrapping paper roll support, an unwinder, a dancer assembly having a festoon of rollers, a rotary 10 cutter, a stationary cutter, and a pair of pinch rollers driven by another tr~ncmicci-~n The rotating carousel rotates vithin the frame and is driven by the motor and tr~ncmiccinn Each wrapping pocket has ~Ccori~t~d with it a pair of stuffer spindles, a pair of star wheels, and movable pocket clamp and underfold devices.

The wound rolls of paper product or workpieces to be wrapped are fed into our wrapping machine by a roll infeed conveyor. The wound rolls or workpieces enter our wrapping machine such that their center tubes are in an axial direction withrespect to the rotating carousel of the wrapping machine. The infeed conveyor 2 0 can be placed on either side of the wrapping machine carousel.
Roll infeed conYeyors are well known in the art. Any infeed conveyor capable of delivering the workpiece to our wrapping machine in the proper orientation couldbe used. The preferred roll infeed conveyor is the one taught and disclosed in U.S.
2 5 Patent No. 4,360,098 entitled INFEED CONVEYOR issued on 23 November 1982.
s 2 ~ 8~097 The roll infeed conveyor taught and disclosed in U.S. Patent No. 5,050,724 entitled ROLL INFEED CONVEYOR issued on 24 September 1991 could be used as well.
The sperific~tion~ of the 4,360,098 and 5,050,724 patents are incorporated herein by reference.

The wrapping paper utilized by our wrapping machine typically comes in a large roll. An axle or shat is placed through the center core of the wrapping paper roll and the roll is rotatably supported on the axle by a pair of roll lifter arms along one side of our wrapping machine. An unwinding device including a unwind belt 10 rests on the top of the wrapping paper roll and applies a predetermined force to the wrapping paper roll in order to accelerate, decelerate and uniformly feed wrapping paper to our wrapping machine. The function of the unwinding device is to meet the wrapping paper demand of the wrapping machine and eliminate the possibility of the wrapping paper being torn as it is drawn into the wrapping 1 5 machine.
The wrapping paper is unwound from the paper roll by the unwinder and is drawn into the wrapping machine by a pair of pinch rollers. The pinch rollers are driven by a tr~nemi~ei~n which can be engaged and disengaged. Upon 20 entering the machine, the wrapping paper is threaded through the festoon of rollers of the dancer assembly. A set of upper rollers are mounted to the machine frame and a set of lower rollers are mounted on a pair of pivotable dancer arms.The purpose of the dancer arms is to prevent tearing of the wrapping paper when the wrapping machine is first started. The dancer arms are also used as a 2 5 control device for the unwinder belt.

2 1 8~397 ' ~
In the idle mode, the carousel of our invention rotates at a predetermined rate A
sensing device, typically an electric eye, is attached to the infeed conveyor todetermine the presence of workpieces to be wrapped. If a workpiece is not sensed, 5 wrapping paper is not fed into the machine. ~Vhen the first workpiece to be wrapped is sensed by the device and enters the wrapping machine, there is an immediate acceleration of the wrapping paper from rest to a wrapping paper speed predetermined by the amount of wrapping paper required to band and wrap one workpiece in one machine cycle. For reasons that will become evident, the 10 predetermined wrapping paper speed is always less than the predetermined speed of the carousel.
When the sensing device determines the presence of a workpiece, the pinch rollertrs~n~miq~iQn engages and draws the wrapping paper into the machine. If the 15 wrapping paper, which is relatively thin, was drawn by the pinch rollers directly from the large paper roll, the wrapping paper would likely tear during the initial acceleration. To prevent tearing, before engaging the pinch rollers, the wrapping paper is threaded up and down oYer a plurality of paper rollers which form the dancer assembly. The upper rollers are fixed to the machine frame. The lower 2 0 rollers are mounted to a pair of pivoting dancer arms or bars.
Even with the aid of the unwinder belt, the roll of wrapping paper canrlot be sllfficiPntly accelerated to meet the paper demand rate of the machine. When thefirst workpiece enters the machine and the paper roll is at rest, the greater rate of wrapping paper acceleration required by the machine is c~ d for by the 2 ~ 80097 I
web of paper threaded through the festoon o~f rollers. As the paper is ~cr~l~tPdinto the machine, the pivoting bars to which the lower rollers are attached rnoYe upward toward the upper rollers to cr~mppns~tp for the accelerating paper demand. Through electro-mechanical means, the pivoting bars are connected to 5 the paper roll unwinder. As the pivoting bars raise, the unwinder belt engagesand unwinds wrapping paper from the roll. As the unwinder accelerates and continues to unwind~ the pivoting bars now fall from their raised position to anequilibrium position where the wrapping paper is fed into the machine at a rate less than the rate at which the machine is operating.
t 0 Because the rolls of wrapping paper are heavy, the roll lifter arms that supportthe axle can be raised and lowered. Any type of lifting m~rh~niqm, such as pnellmAtiC, hydraulic or ball screw lifters, can be utilized. When a new roll ofwrapping paper is to be loaded, the axle is inserted through the roll center, the 15 roll is pocit~ioned between the two lifter arms, and the pair of arms raise the roll so that the roll can freely rotate on the axle.
When the lifter arms are lowered to install a new roll, the unwinding ~.~P. l,_.,;,~...
simultaneously raises off of the old roll high enough so as to not interfere with the 20 new roll to be installed. As the newly installed roll is raised, the unwinding merh~ni~m cimllltslnpously lowers into contact with the top of the new paper roll.
As previously stated, the wrapping paper is drawn into our wrapping machine between a pair of pinch rollers which can be engaged and disengaged by a 2 ~ transmission. Next, a rotary blade scores or perforates the wrapping paper at a ~ ` 2~80 predet~ d position. The rotary blade works in conjunctPon ;7ith a knife. The knife has one or more nicks so that the rotary blade does not cut the entire width of the wrapping paper. The knife can be moved up into an engaged cutting position or down into a non-cutting position.
-The rotary blade cuts the wrapping paper to a predetermined length. The lengthis determined by adding the workpiece circumference and the required wrapping paper lap. The lap is typically one inch.
10 The paper is then fed downward by the pinch rollers toward the rotating carousel m~rh~nicm at a speed rate slower than that of the rotating carousel. Below the carousel are located twin timing belts which each contain small raised portions or tabs. The speed of the timing belts matches the speed of the outside diameter of the carousel. On the outside diameter of the carousel are located vacuum blocks,1 5 one adjacent to each pocket. As the carousel vacuum block and one of the tabs on each belt come together, the wrapping paper is captured between the vacuum block and the respective tab of each belt. The speed differential between the pinch rollers and the faster speed of the timing belts and the vacuum blocks on the outside diameter of the carousel causes the wrapping paper to burst or tear at the 2 0 perforation.
This action transfers individual sheets of wrapping paper onto ~he carousel in the correct location for each pocket opening. Each vacuum block is located above each carousel pocket. After the perforation is torn and the separated sheet is 2 5 transferred to the carousel, a vacuum is applied to the vacuum block, and the tabs 2 ~ 80û97 on the timing belts drop away. The wrapping paper is now attached to the carousel at the va~uum block by vacuum only. The leading portion of the wrapping paper sheet is held by the vacuum, the middle portion of the wrapping paper sheet is positioned so that it covers the pocket opening, and the trailing5 portion of the wrapping paper sheet extends beyond the pocket opening.
As the workpieces tQ be wrapped enter the wrapping machine from the infeed conveyor, they are pushed by the conveyor onto a curved ramp haYing twin ramp surfaces. The ramp extends upward and toward a portion of the carousel, the 10 curvature or arc of the ramp being eccentric to the perimeter of the carousel. As the ramp surfaces extend upward, their bottom surfaces get closer to the outer diameter of the carousel.

At this point one flight, of a plurality of Qights attached to a chain conveyor,contacts the workpiece tangentially at the ramp base and guides it up the ramp into a wrapping station or pocket in the carousel. The flights and pockets are timed such that as each flight rises from the bottom of the machine between the 20 twin ramp surfaces, it remains aligned with a pocket on the carousel. As the carousel rotates at its rate of rotation, the flight pushes the workpiece up the ramp at the same rate of speed and into the pocket.
Because the middle portion of the wrapping paper sheet covers the pocket 2 5 opening, as the ramp and flight guide the workpiece into the pocket, the wrapping 2 1 8~97 psper covers a portion of the workpiece as it also enters the pocket. Once in the pocket, ~ ely 240 degrees of the arcuate surface of the workpiece is covered by the wrapping paper sheet. Only the wrapping paper sheet leading portion and trailing portion extend out of the pocket opening.
To insure that the workpiece fully enters the carousel pocket, an optional poking mPrh~nicm is employed to push the workpiece completely into the poclcet if necessary. The poking merh~nicm is driYen by the same po~ver source that powers the chain conveyor to ~vhich the flights are attached. The mPrh~nism comprises an eccentric structure, a first bar member, a pivoting member, a second bar member, a roller, and a third bar member. The center of the eccentric10 structure is attached to the power source. The first bar member is connected to the edge of the eccerltric structure at one end and to the piYoting member at the other end. The second bar member is connected to the piYoting member at one end and to the axis of the roller on the opposite end. The third bar member is also attached to the axis of the roller on one end and the ~vrapping machine frame onthe other end. The piYoting member has a third connecting point ~hereby the piYoting member is piYotally connected to the ~Yrapping machine frame.

The poking mechanism is timed Yith t~le carousel such that after each workpiecehas been ramped into a pocket, the roller attached to the end of the second bar member extends into the pocket a predetermined distance and engages the ~Yorkpiece thereby pushing the wolkpiece completely into the pocket. The second bar member also includes a compression or suspension mPrll~nicm so that the ~Yorkpiece is not damaged or crushed within the pocket. The compression or 20 suspension merh~nicm has a predetermined compression or cushiorling force rate so that when the ~vorkpiece is fully positioned within the pocket, the second bar member compresses or shortens in length thus preventing damage to the ~vorkpiece. When the workpiece is properly positioned in the pocket, the poking merhslnicm is retracted to its starting position and the compression or suspension mPrh:lnicm re-extends to a predetermined position.
2 5 The poking mechanism roller withdraws completely from the carousel pocket to a location outside of the diameter of the carousel before the pocket opening 2 1 ~0097 sufficiently rotates to a position where the inserted roller would strike the carousel. As each carousel pocket passes the location of the poking mP~h:-nisrn,the roller contacts the workpiece, pushes the workpiece completely into the pocket if necessary, and retracts before the carousel pocket moYes past the poking 5 m~ch~ni.cmc location.
As the workpiece is ramped into contact with the wrapping paper sheet and into the pocket or wrapping station, two folder rod structures, stationary with respect to the carouse~ pocket with which they are associated, which are aligned with the axis of the workpiece, and which are located about 1 It4 inches (3.18 centimeters) 10 beyond the parallel ends of the workpiece roll after full workpiece insertion, contact the excess wrapping paper beyond the wolkpiece ends and begin to fold the wrapping paper toward the center or core of the workpiece.
15 As the carousel continues to rotate and after the workpiece has fully entered the pocket, a clamping mPrh~nicm, including a clamping plate and driven by an underfolder plate linkage, clamps the workpiece and wrapping paper sheet firmly into the pocket. After further carousel rotation an underfolder m-~rh~nicrn, including an underfolder plate conn~rted to an underfolder arm, passes upward 20 and across the opening in the pocket where the wrapping paper and workpiece are now clamped. As the underfolder plate moves up and across the opening, the trailing wrapping paper portion is directed upward and completely over the workpiece. The underfolder plate and clamp hold the trailing wrapping paper portion snugly against the workpiece so that there are no air pockets or gaps 25 between the wrapping paper and the workpiece.

2 1 8~097 The remaining exposed wrapping paper end next encounters a brush mounted to the wrapping machine frame such that its bristles contact the outer diameter surface of the rotating carousel. When the carousel pocket arrives at the location 5 of the brush, the remaining exposed wrapping paper end or leading portion is brushed over the trailing portion of the wrapping paper by the brush bristles toform the lap. The wrapping paper sheet is now fully banded in a cylindrical fashion or tube around the outer circumference of the workpiece. The side edges of the wrapping paper sheet now extend out~ard a predetermined distance 10 beyond the fiat circu~ar parallel sides of the workpiece.
A stuffer me~h~nicm includes a pair of stuffer spindles for tucking the wrapping1 5 paper sheet side edges into the center core are supported by a stuffer actuating block on each side of each pocket. The stuffer spindles are driven by a barrel cam mPrh~ni~m which controls when the stuffer spindles are inserted into the workpiece centers and when the stuffer spindles are retracted from the workpiececenters. The camed stuffer spindle mP~h~ni~m is driven by the rotation of the 2 0 carousel. The barrel cam is attached to the machine frame and is located adjacent the carousel. The diameter of the barrel cam is ap~ ly the same as the diameter of the carousel. Cam followers, which are cnnnP~tPd by linkages to the stuffer spindles, ride in the barrel cam.
2 5 Now that the wrapping paper has fully surrounded the outer ~ ulllrelellce of the work piece and one portion of each side edge is folded toward the workpiece center by the pair of stationary rods, the pair of stuffer spindles first enter the center tube of the workpiece and tuck a first portion of the wrapping paper sheet.
5 The stuffer spind~e mechanisms include a pressure limiting feature which prevents the stuffer spindles from pushing the extended portions of the wrappingpsper into the center. tube of the workpiece with such force that the friction between the stuffer spindles and the wrapping paper, within the confines of the workpiece tube, causes the paper to tear or become damaged.

A wide flat belt is supported by the frame over the top portion of our wrapping machine. The belt is supported by a plurality of pulleys. It is driYen by a number of stationary plates that are attached to the carousel outer periphery. The stationary plates are similar in structure to the underfolder plates except that15 they do not move. When the pocket cont~inin~ the workpiece first comes into contact with the belt, the underfolder plate partially retracts and the belt comes into contact with the exposed portion of the wrapping paper including the lap.
The belt holds the wrapping paper firmly against the ~ during the subsequent folding operations of the wrapping paper sheet around the wo~L~ ~ce 2 0 sides. .
A folder m~rh~nigm including a star wheel, is a]so located on each side of each pocket. Each star wheel has a center axis that is mounted on an arm and is driven by a geneva wheel assembly. The star wheel makes two motions. First, 2 5 the star wheel rotates on its own axis. Second, the star wheel axis moYes in an 2 ~ 7 arc on the arm around a portion of the periphery of the workpiece side. Both motions are ~ mplichF~d by a geneYa wheel assembly, linkage, gearing, and timing belt.
5 Next, the stuffer spindles withdraw and the star wheels on each side of the workpiece driven by the geneva wheel begin to spin on their centers and around aportion of the periphery of the ends of the workpiece. As each star wheel spins, it engages the outer edges of the wrapping paper and folds them against the sides and toward the center of the workpiece. When the star wheels complete their first 10 motion, the stuffer spindles next re-enter the workpiece center thereby tucking the wrapping paper into the workpiece center tube. The stuffer spindles next retract.
The star wheels begin to spin again and move around the remaining portion of the periphery of the workpiece. The star wheels stop and the stuffer spindles stuff a third and final time.

The stuffer spindles must be withdrawn before the star wheels can rotate. Each star wheel has a plurality of points qr sides. When stopped, the stuffer spindles pass through one of the gaps between the star wheel points. If the stuffer spindles were not withdrawn, the star wheel points would strike the stuffer spindles when2 0 they begin to rotate.
In the above example, the stuffer spindles stuff and retract once, then the starwheels spin around 180 degrees of the periphery of the workpiece, the stuffer spindles stuff and retract a second time, the star wheels spin around the 2 5 remaining 180 degrees of the workpiece periphery, and the stuffer spindles stuff 2 1 80~97 ~ and retract a third and final time. The sequence can be varied to include additional or fewer stuffer and/or star wheel cycles and still produce a fully wrapped workpiece.
An alternative folder merh~lnicm is utilized to wrap ~vorkpieces. Thisalternative folder mPrh~niqm may be used in all cases but is belieted most commercially applicable where a more ~r5the~ic~lly pleasing wrap is desired, i.e.
retail store sales . This is especially dcsirable ~vhen the wrapped ~torkpieces are sold at the retail leYel directly to the consumer. The alternative foldeL mrrh~nicm is nearly identical to the folder mrrh~niqm described above except for the addition of another geneva ~Yheel and a bearing surface and the remoYal of a 1 o predetermined portion of teeth on the gearing.
The alternatiYe stuffer rnerh~niqm works as follows: The workpiece enters the pocket partially coYered by the wrapping paper sheet and the initial fold is made as previously described. The stuffer spindles make their initial stroke into theworkpiece center tube ends. After they are withdrawn, the star ~heels on each side of the workpiece begin to spin on their axles (as preYiously described) and1 5 their arms moYe in an arcuate direction around a portion of the periphery of the workpiece. As each star wheel spins and as each arm moYes along the arcuate path, the star wheel ends engage the outer edges of the wrapping paper and fold them against the sides and the toward the center of the workpiece. The stuffer spindles next re-enter the workpiece center tube thereby tucking the ends of thefolded wrapping paper into the workpiece center tube. After the stuffer spindlesretract, the star wheels begin to spin and moYe again.
While the star wheels still moYe in an arcuate motion around the remaining periphery of the workpiece edge, the star ~vheels only rotate on their axles duling a predetermined portion of the remaining arcuate moYement. The result is a more aesthetically pleasing wrapped workpiece.
Non-rotational motion of the star wheels ~Yhile continuing the arcuate motion of2 5 the arms is achieYed by remoYing a predetermined number of teeth from one of 21 8~097 the t~vo gears and by adding another geneva vheel and bearing surface to t~le folder mechanism. The arms that support the star wheel axles and star ~vheels are carried through the non-rotational motion portion of the folder mechanism bythe engagement of an additional geneva wheel with the bearing surface. At the end of the geneva wheel stroke, the gear teeth mesh again and rotational motion of the star wheel is resumed. The shape of the geneva wheel is determined by thenumber of teeth on the larger gear.
Alternatively, the alternative stuffer mPrh~nicm could be described as an actuating structure for a folder merh~nicm The actuating structure comprising a wheel merh~nicm coupled to an axle, an arm, a stationary rod structure, a pa~vl structure, a stationary gear structure, a rotating gear structure, and a geneva wheel structure. The pawl including a bearing surface. The pawl and the stationary gear being coupled to each other and to a rotating carousel mPrh~nicmof an apparatus for wrapping wol-kpieces. The stationary gear having a pluralityof teeth located around a predetermined portion of its outer periphery. The rotating gear being coupled to the geneva wheel. An end of the ~heel mPrh~niSm axle being coupled to the rotating gear and the geneva wheel. The rotating gear and said stationary gear being st-hst~nti~ly engageù with each other. The arm coupling the ~vheel mPrh~nism axle to the stationary rod structure. The stationary rod structure being coupled to the pa~vl structure.
The rotating carousel pocket next rotates to an exit chute where a pair of upperand lower conveyor belts, having a fixed gap and moving linearly at the same rate as the rate of rotatiqrl of the carousel, grips each wrapped workpiece as it is ejected by an ejector bar within the pocket. The conveyor belts carry the virapped workpiece to a discharge conveyor. Once on the discharge conveyor, the wrapped workpieces are transported to a location where they are collated, boxed, cartoned, cased, etc.

2 ~ 80~97 `
Also, an optional gluing mGrh~ni~m can be incorporated into our wrapping machine. The gluing mechanism employs glue guns that apply glue to the wrapping paper prior to wrapping the workpieces. After application of the glue, the glue is a~lowed to dry on the wrapping paper prior to the wrapping of the 5 workpiece. After the workpiece has been banded, a hot belt is utilized to remelt the glue and adhere portions of the wrapping paper to other portions of the wrapping paper. While glue is not required to practice our invention, glue may be desired. A ~v-k,v;~c~, with a glued wrapper has a marketing advantage in that it is perceived as being more sanitary.

~5 s 2 1 80~97 Descriptions of the Drawings Figure lA is a front elevational-view of our wrapping machine;
5 Figure lB is a detailed front elevational view of a pocket as shown in Figure lA;
Figure 2A is a right side elevational view of a stuffer and ejector me~hs~niem;
Figure 2B is a front elevational view of the star wheel belt;

Figure 3 is top plan view of our wrapping machine;
Figure 4 is front elevational view of our wrapping machine showing the frame and control panel;
Figure 6 is a right side elevational view of our wrapping machine;
Figure 6A is a front elevational view of the stuffer spindle barrel cam of our wrapping machine and shows the cam timing-, Figure 6B is a view of the barrel cam of Figure 6A laid flat;
Figure 7 is rear elevational view of our wrapping machine including an optional gluing me~h~niem;

2 1 80~97 ~`
Figure 8 is a front elevational view of the geneva assembly including a stiffener plate.
Figure 9 is a detailed front elevational vie~v of the carousel and the poker 5 merh~ni!;m showing the poker mech:~ni~m in its retracted position.
Figure 10 is a detailed front elevational view of the carousel and the pol;er mPrh~ni~m showing the poker mPrh~nism in its extended position pushing a workpiece into a pocket of the carousel.
10 Figure 11 is an exploded perspective view of the alternative PnlhQ-lim~nt of the folder merhRni~m Figure 12 is a perspective assembly view of the alternative Pmho~imPI~t of the folder mPrh~ni~nn and a workpiece.

2 1 8~097 Detailed Description Although the disclosure hereof is detailed and exact to enaWe those skilled in the art to practice the invention, the physical Pmho~im~nt.e herein disclosed merely5 exemplify the invention which may be embodied in other specific structures.
While the preferred embodiment has been described, the details may be changed without departing fr4m the invention, which is defined by the claims.
Our invention, shown generally in Figures lA, 2A, and 3 - 5, comprises a l 0 wrapping machine 10 for applying a paper wrapper 18 to a roll of bathroom tissue, paper towel, or workpiece 12. Its primary components include an infeed conveyor 20 (Figure 3), a frame structure 30 (Figure lA), a wrapping paper feeder 40 (Figure lA), a main motor 90 and transmission 92 (Figure lA), a rotating carousel m~rh~nicm 100 having a plurality of wrapping stations or pockets 150 15 (Figure lA), and a wrapped product discharge 300 (Figure lA).
An electric three (3) horsepower motor 90 is mounted within frame structure 30.
The motor 90 is coupled to a worm and gear reducer or tr~ncmiccion 92. From tr~nemiceiQn 92, power is distributed to various comrr~n~nt.s of our wrapping 2 0 machine 10 as further described.
The carousel m~rh~nicm 100 is rotatably supported within frame 30 by axle 102 and bearing blocks 32. Axle 102 is covered by a tube 104 which does not rotate. The carousel 100 rotates on its axle 102 and is driven by rotary power derived from 2 5 transmission 92. In our preferred embodiment, the carousel 100 has eight (8) ~ 21 8G097 pockets 150. However, it is to be understood that the number of pockets 150 in carousel 100 could be changed without varying from our invention.
The wound rolls of paper product or workpieces 12 to be wrapped are fed ;nto ourS wrapping machine 10 by a roll infeed conveyor 20. Referring to Figure 3, the phq~mPnt of the infeed conveyor 20 can be seen; however, it could be located on either side of the wr~pping machine 10. Infeed conveyors 20 are well known in the art. The roll infeed conveyor used in our preferred embodiment is the one taught and disclosed in U.S. Patent No. 4,360,098 entitled INFEED CONVEYOR
1 0 issued on 23 November 1982. The workpieces 12 enter our wrapping machine 10such that their center tubes 13 are oriented in an axial direction with respect to the rotating carousel 100 of the wrapping machine 10. The infeed conveyor 20 hasa plurality of fiight bars or pusher rods. The pusher rods are identified at reference numerals 78, 79, and 80 in the 4,360,098 patent. Each aight bar or 15 pusher rod pushes a workpiece 12 into our wrapping machine 10. When the workpiece 12 has been conveyed to the proper location, the flight bar or pusher rod drops below the surface upon which the workpiece 12 is conveyed.
As shown in Figure lA, the wrapping paper feeder 40 includes a wrapping paper 2 0 roll support 42, an unwinder 50, a dancer 60 having a festoon of upper rollers 62 and lower rollers 64, a pair of pinch rollers 80 driven by a second tr~ncmicci- n 82, a rotary cutter 84, and a movable blade 86.
The wrapping paper 15 utilized by our wrapping machine 10 typically comes in a 2 5 large roll 14 as shown in Figures lA, 3, and 4. The wrapping paper is typically a 2 ~ 80097 17 pound paper, although other weights and types of paper could be used. An axle46 is placed through the center core 17 of the wrapping paper roll 14 and the roll 14 is rotatably supported on the axle 46 by a pair of roll lifter arms 44 along one side of our wrapping machine 10.

Because the rolls 14 of wrapping paper 15 are heavy, the roll lifter arms 44 that support the axle 46 can be raised and lowered. As best shown in Figure lA, a ball screw lifter 48 coupled to a motor 49 is connected to the lifter arms 44. When anew roll 14 of wrapping paper 16 is to be loaded, the axle 46 is inserted through the 1 0 roll center 17, the roll 14 is positioned between the two lifter arms 44, and the pair of arms 44 raise the roll 14 so that the roll 14 can freely rotate on the axle 46.
When the lifter arms 44 are lowered to install a new roll 14 an unwinding mPrh~nism 50, discussed in detail below, simultaneously raises off of the old roll 1 5 14 high enough so as to not interfere with the new roll 14 to be installed. As the newly installed roll 14 is raised by ball screw lifter 48, the unwinding mP~hs~nicm 50 ~im"lt~neously lowers into contact with the top of the new paper roll 14.
As best shown in Figure lA, the unwinding ~rrl~ 50 having unwinder belt 2 0 52 rests on the top of the wrapping paper roll 14. The belt is supported by and rotates between a pair of sheaves or pulleys 53. One sheave 53 is driven by a motor 54 which is actuated by a potentiometer switching mef-h~niQm 68 discussed below.The belt 52 applies a predetermined force to the wrapping paper roll 14 in order to accelerate, decelerate, and uniformly feed wrapping paper 15 to our wrapping 25 machine 10.

2 1 ~Ooq7 The wrapping paper 15 is unwound from the paper roll 14 by the unwinder 50 and is drawn into the wrapping machine by a pair of pinch rollers 80. Upon entering the machine 10, the wrapping paper 15 is first threaded beneath a first single roller 56 to a second single roller 58 and then through a festoon of upper rollers 62 and lower rollers 64. The set of upper rollers 62 are mounted to the frame 30 and the set of lower rolleFs 64 are mounted between a pair of pivotable arms 66. Therollers 62 and 64 form dancer 60. The wrapping paper 15 wound through the dancer 60 forms a web 16. The purpose of the dancer 60 and web 16 is to prevent tearing the wrapping paper 15 when the wrapping paper 15 is first fed into the wrapping machine 10.
The rotating shaft of a potentiometer 68 is connected to one of the pivoting arms 66.
The potentiometer 68 controls the speed of unwinder motor 54. When wrapping 1 5 paper 15 is initially drawn in the machine 10, web 16 is shortened and pivoting arms 66 rise. As pivoting arms 66 rise and rotate the shaft on ~oten~i~rn~ter 68, potentiometer 68 actuates unwinder motor 54 so that wrapping paper 15 is unwound from roll 14 by unwinder belt 52.
2 0 The pair of pinch rollers 80 draw the wrapping paper 15 into the machine 10. The pinch rollers 80 are controlled by a tr~ncmiccion 82 which can be engaged and disengaged. Adjacent to the pinch rollers 80 is located a rotary knife 84. A
movable blade 86 is positioned below the rotary knife. When actuated, the movable blade 86 rises ~p~, v~ ately .030 inch (0.0762 ~Pntim~ter) to perforate or score the 2 5 wrapping paper 15 into wrapping paper sheets 18. The paper width is perforated 2 1 8~97 and not completely cut by rotary knife 84 and movable blade 86. Blade 86 includes three notches and the paper 15 is not cut at each notch.
The rotary knife 84 and movable blade 86 perforate the wrapping paper 15 to a 5 predetermined length. The length is determined by adding the workpiece 12 circumference and the required wrapping paper lap. The workpiece diameter varies from 3.5 inches (8.9 centimeters) to 5.5 inches (14.0 centimeters). The lap is typical~y one inch (2.54 ~PntimetPrs) The workpiece 12 length or cut length alsovaries from 3.5 inches (8.9 ~pntin~etprs) to 4.5 inches (11.4 centimeters) In the idle mode, the carousel 100 of our invention 10 rotates at a rate of approximately 12.5 revolutions per minute. An electric eye 28 is attached near the end of the infeed conveyor 20 to determine the presence of workpieces 12 to be wrapped. If a workpiece 12 is not sensed. wrapping paper 15 is not fed into the 1 5 machine 10. When the first workpiece 12 to be wrapped is sensed by the eye 28 and enters the wrapping machine 10, there is an immeA;~tP acceleration of the wrapping paper 15 by the pinch rollers 80 from rest to a speed predetermined by the amount of wrapping paper required to band and wrap one workpiece 12 in one machine cycle. The p-~,d~ ed speed is c~lc~ ted using the diameter of the 2 0 workpiece to be wrapped and the desired lap. In all cases, the predetermined speed will be less than the carousel rate of rotation.
When the eye 28 determines the presence of a workpiece 12, the pinch roller tr~n~nlicci~n 82 engages and draws the wrapping paper 15 into the machine 10.
2 5 If the wrapping paper 15, which is relatively thin, was drawn by the pinch rollers 2 ~ 80097 80 directly from the large paper roll 14, the wrapping paper 15 would likely tear during the initial acceleration. To preYent tearing, before engaging the pinch rollers 80 the wrapping paper 15 is threaded up and down in a web 16 over the plurality of paper rollers 62 and 64 which form the dancer 60.

Even with the aid of the unwinder belt 52, the roll of wrapping paper 14 cannot be sufficiently accelerated to meet the paper demand rate of the machine 10. When the first workpiece 12 enters the machine 10 and the paper roll 14 is at rest, the rate of wrapping paper acceleration imparted by the pinch rollers 80 is 1 0 ~omrPnc~t~d for by the web 16 oF paper 15 threaded through the dancer 60. As the paper 15 is accelerated into the machine 10, the pivoting arms 66 to which the lower rollers 64 are attached pivot upward toward the upper rollers 62 to compensate for the accelerating paper demand. As the pivoting arms 66 rise, the pot~n~iom~tPr 68 actuates the unwinder belt 52 which unwinds wrapping paper 15 15 from the roll 14. As the unwinder 50 accelerates and continues to unwind, thepivoting arms 66 begin to fall from their raised position to an equilibrium position where the wrapping paper 15 is fed to the machine 10 at the same rate the machine 10 is operating.
2 0 The paper 15 is then fed downward by the pinch rollers 80 toward the rotating carousel 100 at a rate of speed slower than that of the rotating carousel. Below the carousel 100 are located twin timing belts 110 which each contain small raised portions or tabs 112. As shown in Figure lA, the timing belts 110 ride on timingbelt sheaves 114 and 115. The speed of the timing belts 110 matches the speed of2 5 the outside diameter of the carousel 100. On the outside diameter of the carousel 2 ~ 80~7 100 are located vacuum blocks 140, one adjacent and above each pocket 150 in carousel 100. As the carousel vacuum block 140 and one of the tabs 112 on each belt 110 come together, the wrapping paper 15 is captured between the vacuum block 140 and the respective tab 112 of each belt 110. The speed differential between the pinch rollers 80 and the carousel 100 causes the wrapping paper 15 to burst or tear at the perforation into individual sheets 18.
This action transfers individual sheets of wrapping paper 18 onto the carousel 100 in the correct location for each pocket opening 152. After the perforation is torn and the separated sheet 18 is transferred, a vacuum is applied to the vacuum block 140 and the tabs 112 on the timing belts 110 drop away. A vacuum motor 142is mounted to frame 30. The vacuum motor 142 is conr ected by a conduit 143 to avacuum manifold 144 located around the axle 102 of rotating carousel 100. From the manifold 144, smaller conduits 145 run to each vacuum block 140. The manifold 144 includes a vacuum valve 146 mounted to frame 30 through suitable brackets and a vacuum drum 148 mounted to axle 102 for applying a vacuum to each vacuum block during the required portion of the carousel cycle.
The wrapping paper sheet 18 is now attached to the carousel 100 at the vacuum 2 0 block 140 by vacuum only. The leading portion of the wrapping paper sheet 18 is held by the vacuum, the middle portion of the wrapping paper sheet 18 covers thepocket opening 152, and the trailing portion of the wrapping paper sheet 18 extends beyond the pocket opening 152.

2~ao97 As each workpiece 12 to be wrapped enters the wrapping machine 10 from the infeed conveyor 20, it is pushed by the conveyor 20 onto a curved ramp 130 that extends upward and around a portion of the carousel 100. The ramp 130 i8 best shown in Figure lA. As the ramp 130 extends upward, its bottom surface 132 gets 5 closer to the outer diameter of the carousel 100.
Also referring to Figure lA, it can be seen that a plurality of flights 120 are attached to a chain conveyor 122. The chain conveyor 122 is driven on a series of sprockets, one of which derives its power from tr~nsmiC~ion 92. The center of the 1 0 arc made by the chain conveyor 122 is the same as the center of the carousel 100 diameter. Thus, the llights 120 remain a fixed distance from carousel 100 as they travel around the arc. A flight 120 contacts the workpiece 12 tangentially at the ramp base 134 and guides the workpiece 12 up the ramp along its bottom surface 132 into a pocket 150 in the carousel 100. The flights 120 and pockets 150 are timed 15 such that as each night 120 rises from the bottom of the machine 10, it is aligned with a pocket 150 on the carousel 100. As the carousel 100 rotates at its rate of rotation, each flight 120 pushes a workpiece 12 up the ramp 130 at the same rate of speed and into a pocket 150. While the flights 120 remain at the fixed distance from the carousel 100, the ramp surface 132 gets closer to the carousel 100 as the 2 0 ramp 130 extends about the carousel 100.
Because the middle portion of the wrapping paper sheet 18 covers the pocket opening 152, as the ramp 130 and ~light 120 guide the workpiece 12 into the pocket 150 the wrapping paper sheet 18 also enters the pocket 150 and surrounds a 2 5 portion of the workpiece 12. Once in the pocket 150, approximately 240 degrees of 2 1 80~97 . the wc,.kl,;e~ 12 is covered by the wrapping paper sheet 18. Only the wrappingpaper sheet 18 leading portion and trailing portion extend out of the pocket opening 152.
To insure that each ~vorkpiece 12 fully enters each carousel pocket 150, an 5 optional poking mechanism 410 is employed to push each ~vorkpiece 12 completely into the pocket 150 if necessary. The poking mPch~nicmC is shown in Figures 9 and 10. The poking mechanism 410 is driven by motor 90 and tr~ncmiscirn 92 which also powers the chain conveyor 122 to which flights 120 are attached. The merh~n;cm 410 comprises the following componPntc an eccentric sheave 420, a first bar member 430, a pivoting nlember 440, a second bar member 450, a roller 460, and a third bar member 470. Axle 422 of the eccentric sheave 420 is attached 1 0 to the same axle that sheave 124 rotates on. End 432 of first bar member 430 is connected to the edge of the eccentric 420 at point 424. End 434 of first bar member 430 is attached to the pivoting member 440 at point 442. An end 452 of second bar member 450 is connected to the pivoting member 440 at point 444 hile end 454 is connected to the axis 462 of the roller 460. The third bar member 470 is also attached to the axis 462 of the roller 460 on an end 4?2. The opposite end 474 is cr,nnPcted to the wrapping machine frame 30. Pivoting member 440 has a third 1 5 connecting point 446 also pivotally connecting it to the wrapping machine frame 30.
The poking mrrhRnicm 410 is timed ~vith the carousel 100 such that after each ~Yorkpiece 12 has been ramped into a pocket 150, roller 460 enters the pocket 150 a predetermined distance and makes contact with the workpiece 12 thereby pushing the workpiece 12 completely into the pocket 150. To prevent damage to the workpiece 12, second bar member 450 also includes a compression or s~crpncion merh~nicm 456. In the preferred embodiment, the second bar member 450 is broken into two pieces that are crnnectP~l by spring. The spring acts as the suspension mPrh~nicm 456 and has a predetermined compression spring rate so that when the ~vorkpiece 12 is fully positioned within the pocket 150, the second bar member 450 compresses or shortens in length thus preventing damage to the 25 workpiece 12. Other types of suspension or compression merh~ni~mc that could be used include reciprocating fluid filled cylinders, biasing mPIh~nismc torsional mPrh~ni~mc, etc. 26 2f ~0~97 ._ .
Roller 460 ~Yithdraws completely from the carousel pocket 150 to a location outside of the diameter of the carousel 100 before the pocket opening 152 sufficiently rotates to a position where the inserted roller 460 ~ ould strike the carousel 100.
As each carousel pocket 150 passes the location of the poking merh~nic~n 410, roller 460 contacts the workpiece 12, pushes the ~ orkpiece 12 completely into the pocket 150 if necessary, and retracts before the carousel pocket opening 152 moves past the poking merh~nicrn location.
Two stationary rods 160, as shown in Figure 2A, are aligned with the axis of theworkpiece 12 and are located about 1 1/4 inches (3.18 centimeters) beyond the parallel ends of the ~orkpiece 12. As the workpiece 12 is ramped into contact with the wrapping paper sheet 18 and into the pocket 150, the rods 160 contact the excess wrapping paper 18 beyond the workpiece 12 ends and begin to fold the wrapping paper 18 toward the center or core 13 of the workpiece 12. The stationary rods 160 remain fixed in place after full workpiece 12 insertion into the pocket 150.
As the carousel 100 continues to rotate and after the workpiece 12 has fully entered the pocket 150, a clamp plate 180 shown in Figure lB, driYen by an underfolder plate linkage 192, clamps the workpiece 12 and wrapping paper sheet 18 firmly into the pocket 150. After further carousel rotation, an llntl~rfnl~r plate 190 passes upward and across the opening 152 in the pocket 150 where the wrapping paper sheet 18 and workpiece 12 are now located. As the underfolder plate 190 moves up and across the opening 152, the trailing wrapping paper portion is directed upward and completely over the workpiece 12.

2 1 ~û0~7 The clamp plate 180 and underfolder plate 190 are driven by an underfolder platelinkage 192. The linkage 192 includes an underfolder cam 194, cam followers 196,conn~ctin~ rods 198, underfolder arms 204, clamp arms 227 including i~ternal 218~97 ear 185, stop blocks 182, clamp plate screws 184, underfolder plate screws 186, pins 189, and springs 188.
The underfolder cam 194 is mounted to tube 104 adjacent rotating carousel 100.
The cam 194 does not rotate. For each pocket 150, a cam follower 196 rides in cam 194. Each cam follower 196 is conn~cted to a conn~ctin~ rod 198 that extends to the corresponding underlbld arm 204.
On the carousel 100 at each pocket 150, an underfolder arrn 204 pivots at pivot 1 0 point 206. The rotation of carousel 100 around non rotating cam 194 moYes connecting rod 198 which in turn moves arm 204 and underfolder plate 190 through an arc around pivot 206 and across pocket opening 152. Figure lB shows the underfolder plate 190 partially through its arc. Dotted lines 191 show its position before bPginnin~ to move through its arc. The motion of underfolder arrn 1 5 204 and plate 190 also controls the motion of clamp plate 180, which piYots about pivot point 206 by means of clamp arm 227. Clamp plate 180 has two functions andderives its motion by the same cam system which moves underfolder plate 190 through its prescribed arc. The functions accomplished by clamp plate 180 are tofirmly clamp workpiece 12 and wrapping paper sheet 18 into pocket 150 and to snugly hold the trailing wrapping paper portion against workpiece 12 to insure atight wrap of paper 18 around workpiece 12.
Underfolder plate 190 also moYes through its arc around the same piYot 206 and deriYes its motion from underfolder arm 204. When llnll~rfo~ r plate 190 is 2 5 located in its fully retracted position 191 about piYot 206 clamp plate 180 is also 2 1 ~OOq7 fully retracted from wulkl~;ece 12, since it also moves through its arc around the same pivot 206, and derives its mûtion from underfolder arm 204 by means of clamp arm 227, stop block 182, clamp plate screw 184, internal ear 185, underfolder plate screw 186 and surface 187.

In its fully retracted position 191, screw 186 bears against surface 187 of underfolder arm 2047 screw 184 is retracted from stop block 182, and spring 188 is fully extended. One end of spring 188 is connected to carousel 100 by pin 189. The other end is connected to clamp arm 227. Stop block 182 is mounted to carousel 1 0 100. Ear 185 is part of arm 227. Since screw 186 is held against surface 187 through the tension of spring 188, as underfolder arm 204 begins moving through its arc, clamp arm 227 also begins to move. As underfolder arm 204 continues through its arc, clamp plate 180 contacts workpiece 12 and wrapping paper sheet 18 and snugly clamps them into pocket 150 by the force derived by the external spring 188. As arm 204 continues through its arc, clamp plate 180 and clamp arm 227 stop moving forward, either by plate 180 squeezing against workpiece 12 or by screw 184 bumping against stop block 182. When the clamp plate 180 has stopped mûving~ underfolder plate 190 continues moving through its full arc and - finishes its function of folding trailing portion of wrapping paper 18 against2 0 workpiece 12.
The underfolder plate 190 and clamp plate 180 hold the trailing wrapping paper portion snugly against the workpiece 12 so that there are no air pockets or gapsbetween the wrapping paper sheet 18 and the workpiece 12.

2 1 80~97 A brush 200 is mounted to the wrapping machine frame 30 such that its bristles202 contact the outer diameter surface of the rotating carousel 100. When each carousel pocket 150 arriYes at the location of the brush 200, the l~ll.ai-i.lg exposed wrapping paper end or leading portion is brushed over the trailing portion of the 5 wrapping paper by the brush bristles 202 to form the lap. The wrapping paper sheet 18 is now fully banded in a cylindrical fashion around the outer circumference of the workpiece 12. The side edges of the wrapping paper sheet extend outward a predetermined distance beyond the f~at circular parallel sides of the workpiece 12.

As best shown in Figure 2A, a pair of stuffer spindles 162 for tucking the wrapping paper sheet 18 side edges into the center core 17 are attached to . onnPctin~ tubes 164 which ride on the stationary rods 160. The stuffer spindles 162 are actuated by stuffer actuating cams followers 166. Each cam follower 166 is 1 5 driYen by a barrel cam 168 which controls when the stuffer spindles 162 are inserted into the workpiece center tubes 13 and when the stuffer spindles 162 are retracted from the workpiece center tubes 13. The upper portion of the barrel cam 168 is shown in detail in Figures 6A and 6B. Figure 6A shows the timing of the barrel cam 168 upper portion including its start portion, insert portions, dwell2 0 portions, withdraw portions, and end portion. The entire camed stuffer spindle mP~h~nicrn 170 is driven by the rotation of the carousel 100. The barrel cam 168 is attached to the frame 30 and is located adjacent the carousel 100. The diameter of the barrel cam 168 is approximately the same as the diameter of the carousel 100.

2 1 ~097 Now that the wrapping paper is fully banded around the outer circumference of the workpiece 12 and one portion of each side edge is folded toward the workpiece center 13 by the pair of stationary rods 160, the pair of stuffer spindles 162 first enter the center tube 13 of the wolk~ ~ce 12 and tuck a first portion of the 5 wrapping paper sheet 18 into the center tube 13.
The force of the stuffer spindles which enter the center tube 13 of workpiece 12 is limited by a spring 167 which is mounted to each spindle tube 164. The cam follower 166 which rides in barrel cam 168 is mounted to a bearing block 165 10 which is free to slide on conn~ctinE~ tube 164. As shown in Figure 2A, the spring 167 is mounted between bearing block 165 and collar 169 which is fixed to tube 164.
On the other side of bearing block 165 is mounted another collar 171 which is also fixed to tube 164. When the barrel cam 168 and cam follower system 170 push the stuffer spindle 162 and a portion of wrapping paper sheet 18 into the center of the 1 5 tube 13 of workpiece 12, resistance may be encountered as the stuffer spindle 162 pushes the gathered portion of paper into center tube 13. When this occurs, spring 167 C~ pl e~aes between bearing block 165 and collar 169, and limits stufflng pressure to that of the compression rate of the spring 167. Collar 171 is used only to maintain the proper lateral location of bearing block 165 to tube 164 2 0 when spring 167 is not compressed during the retracted position of stuffer spindle 162.
A wide flat belt 210 is supported on a series of sheaves 212 mounted to a subframe 214 which is positioned over the top portion of our wrapping machine 10. The 2 5 subframe 214 is pivotally attached to the wrapping machine frame 30 at pivot point 216. The belt 210 is driven by a number of stationary plates 106 that are attached to the carousel 100 outer periphery. The stationary plates 106 are similar in structure to the underfolder plates 190 except that they do not move. When the pocket 150 containing the banded workpiece 12 first comes into contact with the belt 210, the underfolder plate 190 partially retracts but the clamp plate continues clamping the banded wu. k~:cce 12 into the pocket 150. The belt 210 comes into contact with the exp~sed portion of the ~vrapping paper sheet 18 including the lap.
The belt 210 holds the wrapping paper 18 firmly against the workpiece 12 during the subsequent folding operations of the wrapping paper sheet 18 around the workpiece sides.
As best shown in Figure lB, a star wheel 220 is also located on each side of each pocket 150. As also shown in Figure 2A, each star wheel 220 is mounted to a drive axle 222 that is rotatably supported within an arm 224. As shown, the axle 222 is 1 5 supported on one end of the arm 224 and the other end of the arm 222 is supported by and pivots about spindle tube 164.
Now referring to Figures 2A, 2B, and 8, the star wheel 220 makes two motions.
First, the star wheel 220 rotates on its drive axle 222. Second, the star wheel axle 2 0 222 moves in an arc on the arm 224 around a portion of the periphery of theworkpiece side. Both motions are accomplished by a geneva wheel 240, a geneva plate 250, a drive system 260, and a gearing system 270.
The geneva plate 250 is mounted to the carousel tube 104 which does not rotate 2 5 with the carousel 100. A plurality of geneva wheels 240, one for each pocket 150, 2 ~ ~097 are rotatably supported at their centers 242 on axles 244. One end of each axle 244 is connected to the carousel 100 at bearing 108 and the other is connected to stiffener plate 280 at stiffener plate bearing 282. The stiffener plate 280 is supported by bearing 284 over tube 104 and rotates with the carousel 100.

A plurality of cam rollers 262 are mounted to the geneva plate 250 which does not rotate. As the genev~ wheel 240 rotates with the carousel 100, the cam rollers 252 enter the slots 246 in each geneva wheel 240. As each cam roller 252 enters a slot 246, reaches the base 248 of the slot 246, and retracts from the slot 246, the geneva 1 0 wheel 240 rotates one third of a revolution.
Now referring to Figure 2B, the geneva wheel axle 244 is coupled to driven sheave 262 of drive system 260. A belt 264 is threaded around a group of sheaves including sheave 26~, 266, and 267. Sheave 266 is connected to stuffer 6pindle tube 1 5 164. Gear 272 is fixed on the same center as tube 164. Gear 274, fixed to star wheel axle 222, is mounted on arm 224 by suitable bearings. Thus when geneva wheel 240 rotates, the rotational motion is ~- al-~ d directly to the star wheel axle 222 to produce the spinning motion of star wheel 220 and to the gearing system 270 mounted to arm 224. When rotating arm 224 is driven by the geneva wheel 240, 2 0 rotating gear 274 moves around fixed gear 272 which is on the same center as stuffer spindle tube 164.
Sheave 262 contains one and one half as many teeth as sheave 266. Therefore, onethird revolution of geneva wheel 240 turns tube 164 one half revolution. For each 2 5 one third revo]ution of geneva wheel 240, arm 224 moves around one half of the 2~ 80097 periphery of the sides of the workpiece 12 and each star wheel 220 makes one andone half revolutions. One half revolution of the star wheel 220 is derived by the one half revolution of arm 224 around tube 164 and an additional one revolution of motion is produced because gear 272 has twice as many teeth as gear 274.

Referring back to Figure 2B, the purpose of sheaves 265 and 267 is to allow for adjustment of the position of stationary rods 160 for different diameter workpieces 12 without having to change the length of the belt 264. Sheaves 266 and 267 remain at a constant fixed distance from each other. The portion of the belt 264 from 10 sheave 265 to sheave 266 and the portion from sheave 267 to driven sheave 262 are always parallel. When the position of sheave 266, which rotates about stationaryrod 160, is changed, the slack or excess belt portion between sheaves 265 and sheave 266 is ~omp~nc~tPd for by the excess or slack belt portion between sheave267 and driven sheave 262.

After the stuffer spindles 162 withdraw from their initial insertion, the star wheels 220 on each side of the workpiece 12 driven by the geneva wheel 240 begin to spin on their center axles 222 and begin to move on arms 224 around a portion, one half revolution, of the periphery of the ends of the workpiece 12. As each star 2 0 wheel 220 spins, its star points 226 engage the outer edges of the wrapping paper sheet 18 and folds them against the workpiece sides toward the center of the workpiece 12.
When the star wheels 220 complete their first motion, the stuffer spindles 162 re-2 5 enter the workpiece center tube 13 thereby tucking the wrapping paper sheet 18 2 1 soaq7 into the workpiece center tube 13. The stuffer spindles 162 next retract a second time. The star wheels 220 begin to spin again and move around the remaining one half revolution portion of the periphery of the workpiece 12. The star wheels 220 stop and the stuffer spindles 162 stuff a third and final time~

The stuffer spindles 162 must be withdrawn before the star wheels 220 can rotate.
Each star wheel 220-has a plurality of points or sides 226. When stopped, the stuffer spindles 162 pass through one of the gaps between the star wheel points 226. If the stuffer spindles 162 were not withdrawn, the star wheel points 226 would strike the stuffer spindles 162 when the star wheels 220 begin to rotate.
The above described wrapping sequence is the preferred sequence. It is to be understood that the sequence can be varied to include additional or fewer stuffer and/or star wheel cycles and still produce a fully wrapped workpiece 12.

An alternative folder merh~nism 600 is utilized to ~Yrap workpieces. The alternative folder mPrh~nicm 500 is nearly identical to the folder merhr~nicm described above except for the addition of another geneva ~Yheel 510 and a bearing surface 520 and the remoYal of a predetermined portion of teeth on gear 274. Thealternative folder ~nPrh~nicm 500 is shown in Figures 11 and 12.
Referring to Figure 11, the folder mPrh~n;sm 500 can be seen to comprise star ~vheel 220, star wheel axle 222, arm 224, stationary rod 160, stuffer spindle 162, tube 164, a bushing 169, a pawl 510, a stationary gear 520, a rotating gear 530, arld a geneva wheel 540. The star wheel 220, star wheel axle 222, arm 224, stationaryrod 160, stuffer spindle 162, tube 164, and the bushing 169 are identical to thecomponents used in the embodiment previously described. Gear 520 is similar to gear 274 and gèar 530 is similar to gear 2~2.
Pa-YI 510 includes a bearing surface 512 as shown in Figures 11 and 12. Fasteners 21 8~097 514 pass through openings in pawl 510 and similar openings in gear 520 to attachboth structures to the carousel 100. Thus gear 520 does not rotate. Gear 520 hasgear teeth 522 around 320 degrees of its outer periphery. Gear teeth are not located on the remaining 40 degree portion shown at 524.

Gear 530, which has half as many teeth 532 as gear 520, is coupled to geneYa ~vheel 540. The end of star ~heel axle 222 is connected to gear 530 and geneva ~vheel 540 through their central axes. Gear 530 has 36 teeth. Gear 520, without any teeth remoYed, would haYe 72 teeth. Gear 52 is this emh~tlimPnt has 60 teeth.
The ~cs~mhled alternatiYe folder m~rh~nicm is shown in Figure l~. ~ workpiece 12 and a portion of the ~vrapping paper 18 is also sho-vn. As the ~ orkpiece 12 and ~vrapping paper 18 enter the pocket 120 (not shown), stationary rod 160 biases the ends of the wrapping paper 18 inward to-vard the center of the orkpiece. This condition is sho-vn only on one side of Figure 12 for clarity. Howe- er, it is to be understood that this occurs on both sides of the workpiece 12 during normal operation of the present invention 10.
The stuffer spindles 162 malce their initial stroke into the workpiece center tubes 13. After they are ~vithdrawn, the star wheels 220 on each side of the wulk,u ~C~ 12 begin to spin on their axles 222 and their arms 224 move in an arcuate directionaround a,u~Lu~ ately one half of the periphery of the workpiece 12. The rotational motion of each star wheel 220 is produced by gear 530 engaging with gear 520. The arcuate motion of arm 224 is also achieved by gear 530 engaging with gear 520.
As each star wheel 220 spins and as each arm 224 moves along the arcuate path, the star wheel ends 226 engage the outer edges of the wrapping paper 18 and foldthem against the sides and the toward the center of the workpiece 12. The star heels 220 stop and the stuffer spindles 162 next re-enter the workpiece center tube 13 thereby tucking the ends of the folded wrapping paper 18 into the ~vorkpiece center tube 13. After the stuffer spindles 162 retract, the star wheels 220 begin to spin and move again.

21~ 97 ~,Yhile the star wheels 220 still moYe in an arcuate motion around the remainingperiphery of the ~Yorkpiece 12 edge, the star ~Yheels 220 only rotate on their axles 222 during a predetermined portion of the remaining arcuate mo~ement. The }esult is a wrapped workpiece that is rr.ore ~sthP~ir~lly pleasing to the eye of the 5 retail consumer. Non-rotational motion of the star wheels 220 while contin-lin~
the arcuate motion of the arms 224 is achieved by remoYing a predetermined number of teeth from gear 520 at location 524 and by adding a gene~ a wheel 540 and pa~Yl 510 to the folder mPrh~nicm 500. The arms 224 that support the star wheel axles 222 and star wheels 220 are carried through the non-rotational motion portion of the folder mPrh~ni~m 500 by the engagement of the geneva wheel 540 ~vith the pa~Yl 510. At the end of the geneva wheel stroke, the gear teeth 522 of gear 520 mesh again with the gear teeth 532 of gear 530 and rotational motion of the star ~Yheel 220 is resumed. Arcuate motion of arm 224 is never stopped.
In the preferred ~mhori;mPnt, geneYa wheel 540 has six faces 542. Three faces 542a are generally arcuate in shapè and capable of engaging the bearing surface 512 of the pawl 510 so that the faces 542a which engage the bearing surface 512 rides on surface 512 a predetermined distance. In the present case, the predetermined distance is one sixth (lt6) the perimeter of gear 522. The remaining three faces 542b can ha~e any shape; in the preferred Prnho~im~nt the faces 542b are fiat. ~Yhile three faces 542a are preferred, it is to be understood that any multiple of three would be sufficient to produce the required motion from geneva ~Yheel 540. Pa~Yl 510 is not a traditional pawl in that it does not include pivot and does not apply to ratcheting motion. Instead the pawl 510 functions lilse a cam follower having a bearing surface 512.
Referring to Figure lA, the rotating carousel pocket 150 next rotates to an exitconveyor 300 where a pair of upper and lower conveyor belts 302 and 304, having a fixed gap and moving linearly at the same rate as the rate of rotation of the carousel by means of a four bar linkage 306, grips each wrapped workpiece 12 as it 2 ~ 800q7 .
is ejected by an ejector bar 290 within the pocket 150. Upper belt 302 and lower belt 304 pivot on their respective centers 307 and 308 mounted to frame 311 and are driven by one to one crank 309 through link 310. This allows the centers of pulleys 312 and 313 to oscillate in time with the constant speed of each pocket 160 in carousel 100 and allows ejector bar 290 to timely eject fully wrapped workpiece 12 between belts 302 and 304.

34 c .~ .
Each ejector bar 290 of each pocket 150 is actuated by an ejector bar cam 292. The cam 292 is mounted parallel to the carousel 100 by means of bracketing which is fixed to frame 30. The cam 292 is stationary and does not rotate. The first end of a c~nnrc~in~ rod 294 is connected to the ejector bar 290 and is guided by linear bearing 295. The opposite end is connected to a cam follower 296 which rides in cam 292. When a rotating carousel pocl;et 150 comes into alignment with the exitconveyor 300, the ejector bar 290 and connecting rod 294 are pushed outward by the cam follower 29~ which lides in the cam ~92. The Yrapped workpiece 12 is ejected 1 0 into exit conveyor 300 between belts 302 and 304.
The conveyor belts 302 and 304 cal~y the wrapped workpiece 12 to a discharge conveyor 310. Once on the discharge conveyor 310, the wrapped workpieces are transported to a location where they are collated, boxed, cartoned, cased, etc.

As shown in Figure 7, an optional gluing mPrhAnicm 400 can be incorporated into our wrapping machine 10. The gluing rnerhz~nicm 400 employs glue guns 402 that apply glue to the wrapping paper 15 prior to wrapping the workpieces 12.
After application of the glue, the glue is allo-Yed to dry on the wrapping paper 15 20 prior to the ~vrapping of the workpiece 12. After the wrapping paper sheet 18 has been banded about the periphery of the wo~k~iece by the pocket 150, underfolder plate 190 and brush 200, heat is applied to belt 210 which remelts the glue and adheres the lapped portions of the wrapping paper to each other. While glue is not required to practice our invention, glue may be desired.

Claims (19)

1. An apparatus for wrapping workpieces, the apparatus comprising:
a frame structure;
a rotating carousel mechanism having a plurality of wrapping stations, the carousel mechanism coupled to the frame structure;
each wrapping station having a clamping mechanism, an underfolding mechanism, a plurality of folder rod structures, a plurality of stuffer mechanisms, and a plurality of folder mechanisms;
the clamping mechanism pivotally mounted to the carousel mechanism adjacent each wrapping station;
the underfolding mechanism pivotally mounted to the carousel mechanism adjacent each wrapping station;
the stuffer mechanisms retractably mounted to the carousel mechanism adjacent each wrapping station;
the folder mechanisms rotatably and pivotally mounted to the carousel mechanism adjacent each wrapping station.

2. The apparatus of claim 1 wherein the clamping mechanism comprises:
a clamp plate;
a clamp arm having a first end, a second end, and a pivot point;
the first end connected to the clamp plate and the pivot point pivotally connected to the carousel mechanism;
a spring having two ends, the first spring end connected to the second clamp arm end and the second spring end connected to the carousel mechanism;
an adjustable ear attached to the clamp arm between the pivot point and the second end;
a caming mechanism for pivoting the clamp plate, the caming mechanism contacting the ear.

3. The apparatus of claim 1 wherein the underfolding mechanism comprises:
an underfolder plate;
an underfolder arm having a first end, a second end, a pivot point, and an actuating point;
the first end connected to the underfolder plate and the pivot point pivotally connected to the carousel mechanism;
a caming mechanism for pivoting the underfolder plate, the caming mechanism connected to the arm at the actuating point.

4. The apparatus of claim 1 wherein the stuffer mechanisms comprise:
a barrel cam mounted to the frame;
a cam follower located within the barrel cam;
a stuffer spindle;
a connecting tube having first and second ends, the connecting tube riding on the folder arm, the first tube end connected to the cam follower and the second tube end connected to the stuffer spindle.

5. The apparatus of claim 4 further including a spring having a first end and a second end;
the first spring end biased against the stuffer spindle;
the second spring end connected to the tube.

6. The apparatus of claim 1 wherein the folder mechanisms comprise:
a geneva wheel assembly mounted to the frame and to the carousel mechanism;
a star wheel having a plurality of points, the star wheel mounted on an axle;
a star wheel arm, the star wheel arm rotatably supporting the axle and pivotally mounted to the carousel mechanism;
the geneva wheel assembly rotating the star wheel and pivoting the star wheel on the star wheel arm about the workpiece.

7. An apparatus for wrapping workpieces, the apparatus comprising:
a frame having a first cam, a second cam, and a geneva wheel assembly;
the first cam, second cam, and geneva wheel assembly connected to the frame;
a rotating carousel mechanism having sides and a plurality of wrapping pockets, the carousel mechanism rotatably mounted within the frame;
each pocket having a clamping mechanism and an underfolding mechanism, the clamping and underfolding mechanisms pivotally attached to the carousel mechanism and connected to the first cam;
a pair of stuffer mechanisms slidably mounted on each side of each carousel mechanism pocket, the stuffer mechanisms connected to the second cam;
a pair of folder mechanisms rotatably and pivotally connected to the carousel mechanism, the folder mechanisms rotated and pivoted by the geneva wheel assembly.

8. A carousel wrapper for wrapping workpieces, the carousel wrapper comprising:
a frame;
a rotating carousel having sides and a plurality of pockets, the rotating carousel supported within the frame;
each pocket having a clamp plate, a clamp arm, an underfolder plate, an underfolder arm, a pair of folder rods, a pair of stuffer spindles, a pair of star wheel arms, and a pair of star wheels;

the clamp plate mounted to the clamp arm and the underfolder plate mounted to the underfolder arm;
the clamp arm and underfolder arm pivotally attached to the carousel;
the folder rods mounted to the carousel, one rod on each carousel pocket side;
one stuffer spindle mounted on each rod;
the star wheel arms pivotally mounted to the carousel, one on each carousel side;
one star wheel rotatably mounted on each star wheel arm.

9. The apparatus of claim 8 further including:
a cam mounted to the frame;
a cam follower riding in the cam;
a connecting rod having a first and a second end, the first end connected to the cam follower and the second end connected to the underfolder arm.

10. The apparatus of claim 8 further including:
an ejector bar mounted within each pocket;
a cam mounted to the frame;
a cam follower riding in the cam;
a connecting rod having a first and second end, the first end connected to the cam follower and the second end connected to the ejector bar.

11. The apparatus of claim 8 further including:
a geneva plate mounted to the frame;
a plurality of cam followers mounted to the geneva plate;
a plurality of geneva wheels mounted to geneva wheel shafts;
each geneva wheel shaft rotatably mounted to the carousel and coupled to a first sheave;
a second sheave connected to each star wheel arm;
a belt connecting the first and second sheaves;
the star wheel arm pivotally mounted to the carousel;
each star wheel rotatably mounted within the arm.

12. The apparatus of claim 8 further including:
an infeed conveyor connected to the frame.

13. The apparatus of claim 8 further including:
an exit conveyor connected to the frame;
the exit conveyor comprising an upper belt and lower belt, the belts mounted a fixed distance apart and on pivot points;
a linkage pivoting the belts on the pivot points.

14. An apparatus for wrapping workpieces, the apparatus comprising:
a frame;
a rotating carousel having a plurality of pockets, the carousel supported within the frame;
an underfolder arm, clamp arm, and a pair of star wheel arms pivotally mounted to the carousel at each pocket;
a pair of folder rods mounted to the carousel at each pocket;
an underfolder plate attached to the underfolder arm and a clamp plate attached to the clamp arm;
a stuffer spindle slidably mounted on each folder rod;
a barrel cam mounted to the frame and having barrel cam mechanisms;
the barrel cam mechanisms connected to the stuffer spindles;
a geneva wheel assembly mounted to the frame and to the carousel;
the geneva wheel assembly coupled to the star wheel arms;
a star wheel rotatably supported by each star wheel arm.

15. An apparatus for wrapping workpieces, the apparatus comprising:
a frame;
an infeed conveyor, the infeed conveyor connected to the frame;
a carousel having a top surface, side surfaces and plurality of pockets, the carousel being rotatably supported on an axle within the frame;
a wrapping paper feeder mechanism for feeding wrapping paper, the wrapping paper feeder mechanism being mounted to the frame;
an exit conveyor, the exit conveyor mounted to the frame;

the wrapping paper feeder mechanism comprising a movable paper roll support, an unwinder mechanism, a dancer assembly, a pair of pinch rollers, and a rotary blade;
the paper roll support and unwinder mechanism mounted to the frame;
the dancer assembly, pinch rollers and rotary blade mounted within the frame;
a ramp mounted within the frame adjacent the carousel, the ramp having a surface, the surface beginning a predetermined distance from the carousel and approaching the carousel as the ramp extends;
a chain conveyor having a plurality of flights, the flights pushing the workpieces up the ramp;
each carousel pocket having a pivotable clamp arm, a pivotable underfolder arm, a pair of folder rods, and an ejector mechanism;
a clamp plate mounted to the clamp arm and an underfolder plate mounted to the underfolder arm;
a first cam mechanism connected to the frame, the first cam mechanism pivoting the clamp and underfolder arms;
a pair of stuffer spindles retractably mounted on the folder rods;
a pair of star wheel arms pivotally mounted to the folder rods;
a pair of star wheels, each star wheel rotatably mounted to one of the star wheel arms;
a second cam mechanism mounted to the frame, the second cam mechanism connected to the stuffer spindles;
a geneva wheel assembly mounted to the carousel and the frame, the geneva wheel assembly pivoting the star wheel arms and rotating the star wheels;

a third cam mechanism mounted to the frame, the third cam mechanism connected to the ejector mechanism;
the exit conveyor comprising an upper belt and a lower belt, the upper and lower belts spaced a predetermined distance apart and pivoting on pivot points;
a linkage connected to the frame and to the upper and lower belts for pivoting the belts at their pivot points.

16. A method of wrapping substantially cylindrical workpieces in a carousel wrapping machine, the workpieces having at least two substantially parallel sides and an opening extending through the workpiece, the method comprising the steps of:
placing a sheet of wrapping material having a first end and a second end between a workpiece and an opening;
pushing the workpiece and wrapping material into the opening;
folding the first end and second end over the workpiece to form, substantially, a tube shape having open ends extending away from said substantially parallel sides of said workpiece;
sequentially tucking, the open ends into the opening extending through the workpiece, and folding any remaining wrapping material against the substantially parallel sides of the workpiece;
ejecting the workpiece from the pocket.

17. The apparatus of claim 1 further including a poking mechanism comprising: an eccentric structure, a first bar member having a first end and a second end, a pivoting member, a second bar member having a first end and a second end, a roller, and a third bar member having a first end and second end;
the first bar member is coupled to an edge of the eccentric structure at its first end and to the pivoting member at its second end; the second bar member is coupled to the pivoting member at its first end and to the axis of the roller on its second end; the third bar member is coupled to the axis of the roller on its first end and the wrapping machine frame at its second end; the pivoting member includes a third coupling point pivotally coupled to the frame structure.

18. The poking mechanism of claim 17 wherein the second bar member includes a compression/suspension mechanism.

19. An actuating structure for a folder mechanism, said actuating structure comprising a wheel mechanism coupled to an axle, an arm, a stationary rod structure, a pawl structure, a stationary gear structure, a rotating gear structure, and a geneva wheel structure; the pawl including a bearing surface;
the pawl and the stationary gear being coupled to each other and to a rotating carousel mechanism of an apparatus for wrapping workpieces; the stationary gear having a plurality of teeth located around a predetermined portion of its outer periphery; the rotating gear being coupled to the geneva wheel; an end of the wheel mechanism axle being coupled to the rotating gear and the geneva heel; said rotating gear and said stationary gear being substantially engaged with each other; said arm coupling the wheel mechanism axle to the stationary rod structure; said stationary rod structure being coupled to the pawl structure.