CA2208907A1 - 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 directedinto 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. Alternative folder mechanisms include folding fingers. The method of wrapping is also disclosed.

Description

PATENT
Atty Docket No. 6109-12416B

Wrapping Machine and Method This is a Continuation-in-Part of Patent Continuation-in-Part Application Serial No. 08/60~,262 filed on 12 January 1996, now abandoned, which was a Continuation-in-Part of U.S. Parent Patent Application Serial No. 08/496,646 filed on 28 June 199~, now abandoned.

Field of Invention The present invention relates to the field of packaging machines for packaging workpieces. Specifically, the present invention relates to the packaging of workpieces made fiom 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 manufactured. This is especially true when only a small number of rolls are packaged together or when each roll is wrapped separately.

A holding area or accumulator is typically established between the paper winder that forms the rolls and the wrapping machine to hold the overflow of rolls or workpieces waiting to be wrapped. The accumulator is used for two primary reasons. First, if the wrapping machine malfunctions or must be shut down for repair, the ~vinder can continue to wind paper rolls from the parent or material roll and does not have to be shut down. The wound rolls are stored in the accumulatoruntil the ~vrapping machine is rl-nning 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 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 change takes approximately 20 minutes. The goal is to change the parent roll, restart the winder and begin producing w ound paper rolls again before the wrapper has wrapped all of the rolls in the accumulator. If the goal is achieved, the wrapping 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 ~vound roll so that the leading edge of the wrapping paper can be adhered to the wound roll. The wound roll is then rotated to draw the wrapping paper around the outer periphery of the roll. Besides adding extra e~cpense to the machine and the wrapped product, glue is typically messy and caneasily clog in the wrapping machine.

Prior art wrapping machines also suffer from a not insubstantial 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 re-vrapped or disposed o~ While some prior art machines are capable of wrapping at substantially the same rate as our wrapping machine, 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 for the winder to fill the accumulator, the winder must be shut down as well.

Additionally, even if the prior art machines are functioning normally ancVor 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 number of rolls wlapped 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 ha~ing the same reliability. Our machine is highly reliable and has a very low scrap rate. Unlike known high rate machines, OUl wrapping machines does not 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 wrapperutilizes a rotating carousel having a plurality of pockets. The wrapping paper and wound roll or ~vorkpiece are sequentially fed into each pocket as the carousel rotates and the wrapping process occurs as the carousel makes one complete revolution. Afully ~vrapped ~vorkpiece 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 carousel is rotated.

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 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 wrappingmachine that utilizes a pair of geneva wheel driven star wheels 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 ~ orkpiece and tuck the w rapping paper into the worl;piece center tube. It is another object of our invention to apply the wrapper around the workpiece in a neat and secure fashion such thatthe 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 easily moved, and is flexible with respect to the location of its infeed and exit 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 OUI invention.

Summary of the Invention OU1 invention comprises a wlapping machine for wrapping rolls of bathroom 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 substantially circular substantially parallel outer sides or flat sides, and a center tube.

OUI invention's primary components include a roll infeed conveyor, a wrapping paper feeder, a frame structure, a main motor and transmission, a rotating carousel mechanism having 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 cutter, a stationary cutter, and a pair of pinch rollers driven by another transmission. The rotating carousel rotates within the frame and is driven by the motor and transmission. Each wrapping pocket has associated 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 ~vrapping machine by a roll infeed conveyor. The wound rolls or workpieces enterOUI ~vrapping machine such that their center tubes are in an axial direction with respect to the rotating carousel of the ~vrapping machine. The infeed conveyor can be placed on either side of the wrapping machine carousel.

Roll infeed conveyors 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 prefelred roll infeed conveyor is the one taught and disclosed in U.S.
Patent No. 4,360,098 entitled INFEED CONVE~OR issued on 23 ~rovember 1982.
The roll infeed conv~eyor taught and disclosed in U.S. Patent No. 5,0aO,724 entitled ROLL INFEED CONVEYOR issued on 24 September 1991 could be used as ~ ell.
The specifications 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 shaft 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 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 ~vrapping machine. The function of the unwinding device is to meet the ~vrapping paper demand of the ~vrapping machine and eliminate the possibility of the wrapping paper being torn as it is drawn into the wrapping machine.

The ~vrapping 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 transmission which can be engaged and disengaged. Upon 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 ~vrapping paper when the wrapping machine is first started. The dancer arms are also used as a control device for the unwinder belt.

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 ~vorkpieces to be ~vrapped. If a workpiece is not sensecl, ~vrapping paper is not fed into the machine. When the first wolkpiece 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 speedpredetermined by the amount of wrapping paper required to band and wrap one workpiece in one machine cycle. For reasons that will become evident, the 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 rollertransmission engages and draws the ~vrapping paper into the machine. If the wrapping paper, which is relatively thin, was dra-vn 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 over a plurality of paper rollers which form the dancer assembly. The upper rollers are fixed to the machine frame. The lower 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 cannot be sufficiently accelerated to meet the paper demand rate of the machine. When the first workpiece enters the machine and the paper roll is at rest, the greater rate of wrapping paper acceleration required by the machine is compensated for by the web of paper threaded through the festoon of rollers. As the paper is accelerated into the machine, the pivoting bars to which the lower rollers are attached move upward tow, ard the upper rollers to compensate for the accelerating paper demand.

Through electro-mechanical means, the pivoting bars are connected to the paper roll unwinder. As the pivoting bars raise, the unwinder belt engages and unwindswrapping paper from the roll. As the unwinder accelerates and continues to unwind, the pivoting bars now fall from their raised position to an equilibrium position where the wrapping paper is fed into the machine at a rate less than the rate at which the machine is operating.

Because the rolls of ~ rapping paper are heavy, the roll lifter arms that support the axle can be raised and lowered. Any type of lifting mechanism, such as pneumatic, hydraulic or ball screw lifters, can be utilized. When a new roll of wrapping paper is to be loaded, the axle is inserted through the roll center, the roll is positioned bet-veen the two lifter arms, and the pair of arms raise the roll so that the roll can freely rotate on the axle.

~Vhen the lifter arms are lowered to install a new roll, the un-vinding mechanism simultaneously raises off of the old roll high enough so as to not interfere with the new roll to be installed. As the newly installed roll is raised, the unwinding mechanism simultaneously 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 transmission. Next, a rotary blade scores or perforates the wrapping paper at a predetermined position. The rotary blade works in conjunction with 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 length is determined by adding the workpiece circumference and the required wrapping paper lap. The lap is typicall~ one inch.

The paper is then fed downward by the pinch rollers toward the rotating carouselmechanism 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 blocl;s, one acljacent to each pocket. As the carousel vacuum block and one of the tabs on each belt come together, ~he 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 perforation.

This action transfers individual sheets of wrapping paper onto the 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 transferred to the carousel, a vacuum is applied to the vacuum block, and the tabs on the timing belts drop away. The wrapping paper is now attached to the carousel at the vacuum 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 trailing portion of the wrapping paper sheet e~ctends beyond the pocket opening.

As the workpieces to be wrapped enter the wrapping machine from the infeed conveyor, they are pushed by the conveyor onto a curved ramp having twin ramp surfaces. The ramp extends upward and toward a portion of the carousel, the 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.

~ CA 02208907 1997-06-26 At this point one flight, of a plurality of flights 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 t~vin ramp surfaces, it remains aligned with a pocket on the carousel. As the carouselrotates 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 opening,as the ramp and flight guide the workpiece into the pocket, the wrapping paper covers a portion of the workpiece as it also enters the pocket. Once in the pocket, approximately 240 degrees of the arcuate surface of the workpiece is covered by the ~vrapping paper sheet. Only the wrapping paper sheet leading portion and trailing portion extend out of the pocket opening.

To insure that the wolkpiece fully enters the carousel pocket, an optional poking mechanism is employed to push the workpiece completely into the pocket if necessary. The pol;ing mechanism is driven by the same power source that powers the chain conveyor to which the flights are attached. The mechanism comprises aneccentric, a first bar member, a pivoting member, a second bar member, a roller,and a third bar member. The center of the eccentric is attached to the power source. The first bar member is connected to the edge of the eccentric at one end and to the pivoting member at the other end. The second bar member is connected to the pivoting member at one end and to the axis of the roller on the opposite end.
The third bar memeber is also attached to the axis of the roller on one end and the the w rapping machine frame on the other end. The pivoting member has a third connecting point whereby the pivoting member is pivotally connected to the wrapping machine frame.

~ CA 02208907 1997-06-26 The poking mechanism is timed with the carousel such that after each workpiece has been ramped into a pocket, the roller attached to the end of the second bar member enters the pocket a predetermined distance and makes contact with the workpiece thereby pushing the workpiece completely into the pocket. The second bar member also includes a compression mechanism so that the workpiece is not damaged Ol crushed within the pocket. The compression mechanism has a predetermined compression force rate so that when the workpiece iâ fully positioned within the pocket, the second bar member compresses or shortens in length thus preventing damage to the workpiece.

The poking mechanism roller withdraws completely from the carousel pocket to a location outside of the diamater of the carousel before the pocket opening suffiently rotates to a postion where the inserted roller ~vould strike the carousel. Aâ each carousel pocket passes the location of the poking mechanism, the roller contacts the workpiece, pushes the workpiece completely into the pocket if necessary, and retracts before the carousel pocket moves past the poking mechanims location.

As the ~vorkpiece is ramped into contact with the wrapping paper sheet and into the pocket or wrapping station, two folder rod structures, stationary w ith respect to the carousel pocket with which they are associated, which are aligned with the axis of the ~vorkpiece, and which are located about 1 1/4 inches (3.18 centimeters) beyond the parallel ends of the workpiece roll after full workpiece insertion, contact the excess wrapping paper beyond the workpiece ends and begin to fold the wrapping paper toward the center or core of the workpiece.

As the carousel continues to rotate and after the workpiece has fully entered the pocket, a clamping mechanism, 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 mechanism, including an underfolder plate connected to an underfolder arm, passes up~vard and across the opening in the pocket where the wrapping paper and ~vorkpiece are nowclamped. As the underfolder plate moves up and across the opening, the trailing wrapping paper portion is directed upward and completely over the tvorkpiece. The underfolder plate and clamp hold the trailing wrapping paper portion snugly against the ~vorl;piece so that there are no air pockets or gaps bet- een the wrapping paper and the worl;piece.

The remaining exposed ~vrapping paper end next encounters a brush mounted to the wlapping machine frame such that its bristles contact the outer diameter surface of the rotating carousel. When the carousel pocket arrives at the location 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 to form 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 e~tend outward a predetermined distance beyond the flat circularparallel sides of the workpiece.

A stuffer mechanism includes a pair of stuffer spindles for tucking the wrappingpaper sheet side edges into the center core are supported by a stuffer actuatingblock on each side of each pocket. The stuffer spindles are driven by a barrel cam mechanism which controls when the stuffer spindles are inserted into the workpiece centers and when the stuffer spindles are retracted from the workpiece centers.
The camed stuffer spindle mechanism is driven by the rotation of the carousel. The barrel cam is attached to the machine frame and is located adjacent the carousel.
The diameter of the barrel cam is approximately the same as the diameter of the carousel. Cam followers, which are connected by linkages to the stuffer spindles, ride in the barrel cam.

No~v that the wrapping paper has fully surrounded the outer circumference of the~ orl; piece and one portion of each side edge is folded to-vard the ~ olkpiece 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.

The stuffer spindle mechanisms include a pressure limiting feature which prevents the stuffer spindles from pushing the extended portions of the wrapping paper into the center tube of the wolkpiece with such force that the friction bet-veen 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 supportecl by the frame over the top portion of our wrappingmachine. The belt is supported by a plurality of pulleys. It is driven 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 that they do not move. When the pocl;et containing the workpiece first comes into contact ~ith 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 workpiece during the subsequent folding operations of the wrapping paper sheet around the workpiece sides.

A folder mechanism, including a star wheel, is also located on each side of eachpocket. 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, the star wheel rotates on its own axis. Second, the star wheel axis moves in an arc on the arm around a portion of the periphery of the workpiece side. Both motions are accomplished by a geneva ~vheel assembly, linkage, gearing, and timing belt.

Next, the stuffer spindles ~vithdraw and the star wheels on each side of the workpiece driven by the geneva ~vheel begin to spin on their centers and around a portion of the periphery of the ends of the workpiece. As each star wheel spins, it engage~ the outel edges of the w rapping paper and folds them against the sides and toward the center of the workpiece. When the star wheels complete their first motion, the stuffer spindles next re-enter the workpiece center thereby tucking the wrapping paper into the ~vorkpiece center tube. The stuffer spindles next retract.
The star wheels begin to spin again and move around the remaining portion of theperiphery of the workpiece. The star wheels stop and the stuffer spindles stuff a third and final time.

The stuffer spindles ~iust be withdra-vn before the star ~vheels can rotate. Each star wheel has a plurality of points or 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 ~vheel points would strike the stuffer spindles when 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 remaining 180 degrees of the workpiece periphery, and the stuffer spindles stuff 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 ~vrapped workpiece.

An alternative folder mechanism is utilized to wrap ~vorkpieces where a more aesthetically pleasing wrap is desired. This is especially desirable when the wrapped workpieces are sold at the retail level directly to the consumer. The alternative folder mechanism is nearly identical to the folder mechanism described above except for the addition of another geneva wheel and a bearing surface and the removal of a portion of teeth on the gearing.

The stuffer spindels make their initial stroke into the ~vorkpiece center tube ends.
After they are withdlawn, the star wheels on each side of the workpiece begin tospin on their a~cles and their arms move in an arcuate direction around a portion of the periphery of the workpiece. As each star wheel spins and as each arm moves along the arcute 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 spindels next re-enter the workpiece center tube thereb~ tucking theends of the folded wrapping paper into the workpiece center tube. After the stufer spindels retract, the star wheels begin to spin and move again.

~hile the star ~vheels still move in an arcuate motion around the remaining periphery of the workpiece edge, the star wheels only rotate on their axles during a predetermined portion of the remaining arcuate movement. The result is a more aesthetically pleasing wrapped workpiece.

Nonrotational motion of the star wheels ~ hile continuing the arcuate motion of the arms is acheived by removing a predetermied number of teeth from one of the gears and by adding another geneva wheel and bearing surface to the folder mechanism.
The arms that support the star wheel axles and star wheels are carried through the nonrotational motion portion of the folder mechanism by the engagement of the geneva wheel with the bearing surface. At the end of the genvea ~vheel stroke, the gear teeth mesh again and rotational motion of the star wheel is resumed.

The rotating carousel pocket next rotates to an exit chute where a pair of upper and lower conveyor belts, having a fixed gap and moving linearly at the same rate asthe rate of rotation of the carousel, grips each wrapped ~,vorkpiece as it is ejected by an ejector bar within the pocket. The conveyor belts carry the wrapped workpieceto a discharge conveyor. Once on the discharge conveyor, the wrapped workpieces are transported to a location where they are collated, boxed, cartoned, cased, etc.

Also, an optional gluing mechanism can be incorporated into our wrapping machine.
The gluing mechanism employs glue guns that apply glue to the ~vrapping paper pl'iOI' to ~ rapping the ~vorkpieces. After application of the glue, the glue is allo-~ ed to dry on the wrapping paper prior to the wrapping of the 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 ~vrapping paper. While glue is not required to practice our invention, glue may be desired. A tt orkpiece with a glued ~~ rapper has a marketing advantage in that it is perceived as being more sanitary.

A second alternatiYe~ folder mechanism is utilized to wrap worli pieces, providing an improved and more aesthetic wrap.

A pair of stuffer spindles are utilized in the alternative folder mechanism. Thestructule of each spindle includes a flat folding surface and a hollo~t center portion.
The stuffel spindles are driven by a barrel cam which is mounted to the wrappingmachine fiame. A plurality of cam follo~ers ride in the cam. A cam follower is connected to each stuffer spindle through a spindle rod. The stuffer spindles advance initiall~ toward the work pieces's center tube ends and act as a mandrelduring the initial fold performed by the folding fingers mechanism. The folding finger mechanism is discussed infra. The spindles are then withdratvn as the initial fold is completed. The stuffer spindle finally advance toward each ~t-ork piece again, this time contacting the ends of the ~vorl; piece and tucking the wrapping papersheet ends into the work piece center core.

As with the previous embodiments, a folder mechanism is mounted on each side of the rotating carousel adjacent to each pocket. In this embodiment, the folder mechanisms comprise folding finger mech~ni.sms. Each folder mechanism is mounted to a crimper plate. A first crimper frame is mounted to the tvrapping machine frame parallel to the rotating carousel. The second crimper frame is mounted on the opposite side of the carousel. This alternative embodiment of thefolder mechanism f nther comprises an activating arm, a lever plate, a plurality of folding fingers, and a connecting link.

Each crimper frame is attached to each side of the carousel at each pocket. The activating arm is pivotally coupled to the crimper frame and the lever plate by means of a pivot shaft. The connecting link has one end coupled to the activating arm, and the other end coupled to at least one folding finger.

An activating arm or crimper cam is mounted to the wrapping machine frame. A
cam follower, engaged within the cam, is attached to an end of the activating arm.
As each activating arm moves along a predetermined path, limited to an arcuate segment by the activating arm cam and a pivot shaft, it activates the folding fingers through the connecting link. The fingers are grouped in pairs, preferably three pairs on each side of the work piece. Each pair of folding fingers has a different configuration to provide accurate folding of the wrapping paper. While the preferred embodiment utilizes three pairs of fingers on each side of the wrapping station, it is to be understood that a lesser or greater number of fingers could be utilized while practicing our invention.

The folding fingers describe a circular path, engaging the outer edge or margins of the wrapping paper and concentrating the outer margin of the paper toward the center of the work piece, thus creating a paper column. As the activating arm reverses its trajectory, the folding fingers retract and the stuffer spindles re-enter the work piece's center tube, thereby folding the wrapping paper against the sides of the workpiece and tucking the column formed by the ends of thè folded wrapping paper into the work piece's center tube. Due to the hollow center of the stufferspindles, the wrapping paper is neatly tucked in and is prevented from unfolding.

It should be understood that each embodiment of the present invention disclosed herein may be described in a preferred embodiment depending upon the commercial concerns regarding the product produced by each embodiment. Therefore, depending upon the desired commercial application each embodiment disclosed herein may separately be considered a best mode of the invention depending upon the goals of the person using the apparatus and/or method disclosed herein.

Descriptions of the Drawings Figure lA is a front elevational view of our wrapping machine;

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 mechanism;

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 andcontrol panel;

Figure 5 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 vie-v of the barrel cam of Figure 6A laid flat;

Figure 7 is rear elevational view of our wrapping machine including an optional gluing mechanism;

Figure 8 is a front elevational view of the geneva assembly including a stiffener plate.

Figure 9 is a detailed front elevational view of the carousel and the poker mechanism sho-ving the poker mechanism in its retracted position.

Figure 10 is a detailed front elevational view of the carousel and the poker mechanism showing the poker mechanism in its extended position.

Figure 11 is an explQded perspective view of the alternative portion of the folder mechanism.

Figure 12 is a perspective vie-v of the alternative portion of the folder mechanism and a workpiece.

Figure 13 is a detailed side elevational view of the second alternative folder mechanism with its fingers in the open position.

Figure 14 is a detailed side elevational view of the second alternative folder mechanism with its fingers in the closed position.

Figure 15 is a front elevational view of the first finger.

Figure 16 is a front elevational view of the second finger.

Figure 17 is a front elevational view of the third finger.

Figure 18 is a cutaway top plan view showing the configuration of the three pairs of fingers.

Figure 19 is a view of the barrel cam of Figure 24 laid flat.

Figure 20 is a fiont elevational view of the second alternative stuffer spindle mechanism.

Figure 21 is a detailed front elevational view of the stuffer spindle.

Figure 22 is a front elevational view of the stuffer spindle and a partially wrapped work piece.

Figure 23 is a cutaway view of a wrapped wolk piece.

Figure 24 is a fiont elevational view of the stuffer spindle barrel cam showing the cam timing.

Figure 2O is a front elevational view of the activating arm or crimping cam.

Figure 26 is a front elevational view of the front side of the rotating carousel.

Figure 27 is a front elevational view of the back side of the rotating carousel.
Figure 28 is a top plan view of the second alternative stuffer spindle mechanism.

Detailed Description Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely 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 from the invention, which is defined by the claims.

~ CA 02208907 1997-06-26 Our invention, shown generally in Figures lA, 2A, ancl 3 - 5, comprises a 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 (FigurelA), a main motor 90 and transmission 92 (Figure lA), a rotating carousel mechanism 100 having a plurality of wrapping stations or pocl;ets 1a0 (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 transmission 92. From transmission 92, power is distributed to various components of our ~ rapping machine 10 as further described.

The carousel mechanism 100 is rotatabl- 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 transmission 92. In our preferred embodiment, the carousel 100 has eight (8) 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 into our~vrapping machine 10 by a roll infeed conveyor 20. Referring to Figure 3, the placement of the infeed conveyor 20 can be seen; however, it could be located oneither side of the wrapping machine 10. Infeed conveyors 20 are well known in the art. The roll infeed conveyor used in our preferred embodiment is the one taughtand disclosed in U.S. Patent No. 4,360,098 entitled INFEED CON TEYOR issued on 23 November 1982. The workpieces 12 enter our wrapping machine 10 such that their center tubes 13 are oriented in an axial direction with respect to the rotating carousel 100 of the wlapping machine 10. The infeed conveyor 20 has a plurality of flight bars Ol pushel rods. The pusher rods are identified at reference numerals 78, 79, and 80 in the 4,360,098 patent Each flight bar or pusher rod pushes a ~orkpiece 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 ~vorkpiece 12 is conveyed ~s shown in Figure lA, the wrapping paper feeder 40 includes a wrapping paper 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 transmission 82, a rotary cutter 84, and a movable blade 86 The ~vrapping paper 15 utilized by our ~ rapping machine 10 typically comes in alarge roll 14 as shown in Figures lA, 3, and 4 The wrapping paper is typically a 17 pound paper, although other weights and types of paper could be used An axle 46 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 1~ are heavy, the roll lifter arms 44 that support the axle 46 can be raised and lowered As best shown in Figure lA, a ballscrew lifter 48 coupled to a motor 49 is connected to the lifter arms 44. When a new roll 14 of wrapping paper 15 is to be loaded, the axle 46 is inserted through the 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.

~Vhen the lifter arms 44 are lowered to install a new roll 14 an un-vinding mechanism 50, discussed in detail below, simultaneously raises off of the old roll 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 mechanism 50 simultaneously lo-vers into contact with the top of the new paper roll 14 As best shown in Figure lA, the unwinding mechanism 50 having unwinder belt 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 mechanism 68 discussed below.
The belt 52 applies a predetermined force to the ~vrapping paper roll 14 in order to accelerate, decelerate, and uniformly feed wrapping paper 15 to our wrapping machine 10.

The wrapping paper 15 is unwound from the paper roll 14 by the unwinder 50 and is dra-vn into the wrapping machine by a pair of pinch rollers 80. Upon enteringthe machine 10, the wrapping paper 15 is ~lrst threaded beneath a first single roller ~6 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 rollers 64 are mounted between a pair of pivotable arms 66. The rollers 62 and 64 form dancer 60. The ~vrapping 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. ~Vhen wrapping 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 potentiometer 68,potentiometer 68 actuates unwinder motor 54 so that wrapping paper 15 is unwound from roll 14 by unwinder belt 52.

The pair of pinch rollers 80 draw the wrapping paper 15 into the machine 10. Thepinch rollers 80 are controlled by a transmission 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 belo-v the rotary knife. ~Vhen actuated, the movable blade 86 rises approximately .030 inch (0.0762 centimeter) to perforate or score the wrapping paper 15 into wrapping paper sheets 18. The paper width is perforated 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 rotaly knife 84 and movable blade 86 perforate the wrapping paper 15 to a predetermined length. The length is determined by adding the workpiece 12 circumference and tbe required wrapping paper lap. The workpiece diameter variesfrom 3.5 inches (8.9 centimeters) to ~.5 inches (14.0 centimeters). The lap is typically one inch (2.54 centimeters). The workpiece 12 length or cut length also varies from 3.5 inches (8.9 centimeters) to 4.5 inches (11.4 centimeters).

In the idle mode, the carousel 100 of our invention 10 rotates at a rate of appro~imately 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 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 immediate acceleration of the ~vrapping 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 predetermined speed is calculated using the diameter of the 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 transmission 82 engages and draws the wrapping paper 15 into the machine 10. If the wrapping paper 15, which is relatively thin, was drawn by the pinch rollers 80 directly from the large paper roll 14, the wrapping paper 15 would likely tear during the initial acceleration. To prevent 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 ~vrapping paper 14 cannot be sufficiently accelerated to meet the paper demand rate of the machine 10 When the first ~vorkpiece 12 enters the machine 10 and the paper roll 14 ia at rest, the rate of wrapping paper acceleration imparted by the pinch rollers 80 is compensated for by the web 16 of paper 15 threaded through the dancer 60 Aâ the paper 16 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 potentiometer 68 actuates the unwinder belt 52 which unwinds ~vrapping paper 15 fiom the roll 14 As the un-vinder 50 acceleratea and continues to unwind, the pivoting arms 66 begin to fall fiom their raised position to an equilibrium position ~ here the wrapping paper 15 ia fed to the machine 10 at the same rate the machine 10 is operating The pal~er 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 timing belt sheaves 114 and 115 The speed of the timing belts 110 matches the speed of the outside diameter of the carousel 100 On the outside diameter of the carousel100 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 bet-veen 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 Ol 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 162 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 142is connected b~ a conduit 143 to a vacuum 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 144includQs a vacuum valve 146 mounted to fiame 30 through suitable bracl;ets 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 ~vrapping paper sheet 18is now attached to the carousel 100 at the vacuum block 140 by vacuum only The leading portion of the wrapping paper sheet 18is held by the v acuum, the middle portion of the wrapping paper sheet 18 covers the pocket opening 152, and the trailing portion of the wrapping paper sheet 18 extends beyond the pocket opening 152.

As each workpiece 12 to be ~vrapped enters the wrappin~ machine 10 from the infeed conveyor 20, it is pushed by the conveyor 20 onto a curved ramp 130 that extends up-vard and around a portion of the carousel 100 The ramp 130 is best shown in Figure lA As the ramp 130 extends up-vard, its bottom surface 132 gets 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 ofsprockets, one of which derives its power from transmission 92 The center of thearc made by the chain conveyor 122 is the same as the center of the carousel 100diameter Thus, the flights 120 remain a fixed distance from carousel 100 as theytravel around the arc A flight 120 contacts the worl;piece 12 tangentially at the ramp base 134 and guides the ~ orkpiece 12 up the ramp along its bottom sur~ace ~ CA 02208907 1997-06-26 132 into a pocket 150 in the carousel 100 The flights 120 and pockets 150 are -timed such that as each flight 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 itsrate 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 ramp 130 extends about the carousel 100 -Because the middle portion of the wlapping paper sheet 18 covers the pocket opening 152, as the ramp 130 and flight 120 guide the workpiece 12 into the pocket 150 the wrapping paper sheet 18 also enters the pocket 150 and surrounds a portion of the workpiece 12 Once in the pocket 150, approximately 240 degrees of the worl;piece 12 is covered by the wrapping paper sheet 18 Only the wrapping paper sheet 18 leading portion and trailing portion extend out of the pocket opening 152 To insure that each worl;piece 12 fully enters each carousel pocket 150, an optional pol;ing mechanism 410 is employed to push each workpiece 12 completely into the pocl;et 150 if necessar~ The poking mech~nims is shown in Figures 9 and 10 The pol;ing mechanism 410 is driven by motor 90 and transmission 92 which also po-vers the chain conveyor 122 to which flights 120 are attached The mechanism 410 comprises the following componts an eccentric 420, a first bar membel 430, apivoting member 440, a second bar member 450, a roller 460, and a third bar member 470 The center 422 of the eccentric 420 is attached to the same axle thatsheave 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 while end 454 is connected to the axis 462 of the roller 460 The third bar memeber 470 is also attached to theaxis 462 of the roller 460 on an end 472 The opposite end 474 is connected to the wrapping machine frame 30 Pivoting member 440 has a third connecting point 446 also pivotally connecting it to the wrapping machine frame 30 The poking mechanism 410 is timed with the carousel 100 such that after each or~;piece 12 has been ramped into a pocket 150, roller 460 enters the pocket 150 a predetelmined distance and makes contact with the workpiece 12 thereby pushing the wolkpiece 12 completely into the pocket 160 To prevent damage to the workpiece 12, secon~ bar member 450 also includes a compression mechanism 456 In the preferred embodiment, the second bar member 450 is broken into two piecesthat are connected by spring The spring has a predetermined compression spring rate so that when the workpiece 12 is fully positioned within the pocket 150, the second bar member 450 compresses Ol' shortens in length thus preventing damage to the workpiece 12 Roller 460 withdra~ s completely fiom the carousel pocket 150 to a location outside of the diamater of the carousel 100 before the pocket opening 152 suffiently rotates to a postion where the inserted roller 460 ~vould strike the carousel 100 As each carousel pocket 150 passes the location of the poking mechanism 410, roller 460 contacts the workpiece 12, pushes the workpiece 12 completely into the pocket 150 if necessar~, and retracts before the carousel pocket opening 152 moves past thepoking mechanism 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 workpiece 12 As the workpiece 12 is ramped into contact with the ~vrapping paper sheet 18 and into the pocket 150, the rods 160 contact the e,lccess wlapping paper 18 beyond the ~vorkpiece 12 ends and begin to fold the w rapping paper 18 toward the center or core 13 of the workpiece 12 The stationary rods 160 remain fi~ed in place after full ~orkpiece 12 insertion into the pocket 150 As the carousel 100 continues to rotate and after the workpiece 12 has fully entered the pocket 1~0, a clamp plate 180 shown in Figure lB, driven 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 underfolder plate 190 passesupward and across the opening 152 in the pocket 150 ~vhere the wrapping paper sheet 18 and ~~or}ipiece 12 are now located. As the underfolder plate 190 moves up and across the opening 152, the trailing wrapping paper portion is directed up~ ard and completely ovel the workpiece 12.

The clamp plate 180 and underfolder plate 190 are driven by an underfolder platelinkage 192. The linkage 192 includes an underfolder cam 194, cam follo-vers 196, connecting rods 198, underfolder arms 204, clamp arms 227 including internal ear185, stop blocks 182, clamp plate screws 184, underfolder plate screws 186, pins189, 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 follo-~er 196 is connected to a connecting rod 198 that extends to the corresponding underfold arm 204.

On the carousel 100 at each pocket 150, an underfolder al m 204 pivots at pivot point 206. The rotation of carousel 100 around non rotating cam 194 moves connecting rod 198 which in turn moves arm 204 and underfolder plate 190 throughan 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 beginning to move through its arc. The motion of underfolder arm 204 and plate 190 also controls the motion of clamp plate 180, ~vhich pivots about pivot point 206 by means of clamp arm 227. Clamp plate 180 has t-vo functions and derives its motion by the same cam system which moves underfolder plate 190 through its presclibed arc. The functions accomplished by clamp plate 180 are to firmly 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 a tight wrap of paper 18 around ~vorkpiece 12 Underfolder plate 190 also moves through its arc around the same pivot 206 and derives its motion from underfolder arm 204 When underfoldel plate 190 is located in its fully retracted position 191 about pivot 206 clamp plate 180 is also fully retracted from work~iece 12, since it also moves through its arc around the samepivot 206, and derives its motion from underfoldel arm 204 by means of clamp arm227, stop block 182, clamp plate screw 184, internal ear 185, underfolder plate screw 186 and surface 187 In its fully retracted position 191, scre~ 186 bears against surface 187 of underfolder arm 204, 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 Theother end is connected to clamp arm 227 Stop block 182 is mounted to carousel 100 Ear 18~ 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 moving, underfolder plate 190 continues moving through its full arc and finishes its function of folding trailing portion of wrapping paper 18 against 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 gapsbetw, een the wlapping paper sheet 18 and the workpiece 12 A brush 200 is mounted to the wrapping machine frame 30 such that its bristles 202 contact the outer diameter surface of the rotating carousel 100 When each carousel pocket 150 arrives at the location of the brush 200, the remaining exposed wrapping paper end or leading portion is brushed over the trailing portion of the wlapping paper by the brush bristles 202 to form the lap The wrapping paper sheet 18 is no-v fully banded in a cylindrical fashion around the outer circumference of the workpiece 12 The side edges of the wrapping paper sheet e~;tend outward apredetermined distance beyond the flat 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 connecting 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 driven by a barrelcam 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, dwell portions, ~vithdraw portions, and end portion The entire camed stuffer spindle mechanism 170 is driven by the rotation of the carousel 100 The barrel cam 168 is attached to theframe 30 and is located adjacent the carousel 100 The diameter of the barrel cam168 is approximatel~ the same as the diameter of the carousel 100 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 ~vorkpiece center 13 by the pair of stationary rods 160, the pair of stuffer spindles 162 first enter the center tube 13 of the ~vorkpiece 12 and tuck a first portion of the 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 which is free to slide on connecting 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 w hich is also fixed to tube 164. ~Then the barrel cam 168 and cam follower system 170 push the stuffer spindle 162 a,nd a portion of wrapping paper sheet 18 into the center of the tube 13 of workpiece 12, resistance may be encountered as the stuffer spindle 162 pushes the gathered portion of paper into center tube 13. ~Vhen this occurs, spring 167 compresses between bearing block 165 and collar 169, and limits st-lffing 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 w hen 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 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 workpiece 12 into the pocket 150. The belt 210 comes into contact with the exposed portion of the wrapping 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 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 referling to Figures 2A, 2B, and 8, the star wheel 220 makes two motions.
First, the star ~vheel 220 rotates on its drive axle 222. Second, the star wheel axle 222 moves in an arc on the arm 224 around a portion of the periphery of the worl;piece side. Both motions are accomplished by a geneva wheel 240, a geneva plate 250, a drive sSstem 260, and a gearing system 270.

The geneva plate 2~0 is mounted to the carousel tube 104 which does not rotate with the carousel 100. A plurality of geneva wheels 240, one for each pocket 150, are rotatably supported at their centers 242 on axles 244. One end of each axle 244 is connected to the caro-lsel 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 252 are mounted to the geneva plate 250 which does not rotate. As the geneva wheel 240 rotates with the carousel 100, the cam rollers 252 enter the slots 246 in each geneva ~vheel 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 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 265, 266, and 267. Sheave 266 is connected to stuffer spindle tube 164.
Gear 272 is fixed on the same center as tube 164. Gear 274, fixed to star ~vheel axle 222, is mounted on arm 224 by suitable bearings. Thus when geneva wheel 240 rotates, the rotational motion is transferred directly to the star ~vheel 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, 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. Therefole, onethird revolution of g~neva wheel 240 turns tube 164 one half revolution. For each one third revolution of geneva wheel 240, arm 224 moves around one half of the periphely 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 ~vorkpieces 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 264from 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 stationary rod 160, is changed, the slack or excess belt portion between sheaves 265 and sheave 266 is compensated for by the excess or slack belt portion between sheave 267 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 wheel 220 spins, its star points 226 engage the outer edges of the wrapping paper sheet 18 and folds them against the workpiece sides to-vard the center of the wor~piece 12.

~Vhen the star wheels 220 complete their first motion, the stuffer spindles 162 re-enter the workpiece center tube 13 thereby tucking the wrapping paper sheet 18 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 ~vheels 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 mechanism 500 is utilized to wrap workpieces where a more aesthetically pleasing wrap is desired. The alternative folder mechanism 500 is nearly identical to the folder mechanism described above except for the addition of another geneva wheel 510 and a bearing surface 520 and the removal of a portion of teeth on gear 274. The alternative folder mechanism is shown in Figuresd 11 and 12.

Referring to Figure 11, the stuffer mechanism 500 can be seen to comprise star wheel 220, star wheel axle 222, arm 224, stationary rod 160, stuffer spindel 162, tube 164, a bushing 169, a pawl 510, a stationary gear 520, a rotating gear 530, and a geneva wheel 540. The star wheel 220, star wheel axle 222, arm 224, stationaryrod 160, stuffer spindel 162, tube 164, and the bushing 169 are identical to the components used in the embodiment previously described. Gear 520 is similar to gear 274 and gear 530 is similar to gear 272.

Pawl 510 includes a bearing surface 512 as shown in Figures 11 and 12. Fasteners514 pass through openings in pawl 510 and similar openings in gear 520 to attachboth structures to the caro--sel 100. Thus gear 520 does not rotate. Gear 520 has gear 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 geneva wheel 540. The end of star ~vheel axle 222 is connected to gear 530 and geneva wheel 540 through their central axes.

The assembled alternative folder mech~nim.s is shown in Figure 12. A workpiece 12 and a portion of the wrapping paper 18 is also shown. As the ~vorkpiece 12 and wrapping paper 12 enter the pocket 120 (not shown), stationary rod 160 biases the ends of the wrapping paper 18 inward toward the center of the workpiece. This condition is shown only on one side of Figure 12 for clairity. Ho~vever, it is to be understood that this occurs on both sides of the workpiece 12.

The stuffer spindels 162 make their initial stroke into the workpiece center tubes 13. After they are withdrawn, the star wheels 220 on each side of the workpiece 12 begin to spin on their axles 222 and their arms 224 move in an arcuate directionaround approximatley 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 arcute path, the star wheel ends 226 engage the outer edges of the wrapping paper 18 and fold them against the sides and the to~vard the center of the workpiece 12. The star wheels 3~

220 stop and the stuffer spindels 162 next re-enter the ~vorkpiece center tube 13 thereby tucking the ends of the folded wrapping paper 18 into the workpiece center tube 13. After the stufer spindels 162 retract, the star ~vheels 220 begin to spin and move again.

~ hile the star wheels 220 still move in an arcuate motion around the remaining periphery of the workpiece 12 edge, the star wheels 220 only rotate on their axles 222 during a predetermined portion of the rem~ining arcuate movement. The result is a more aesthetically pleasing wrapped ~vorkpiece. Nonrotational motion of the star wheels 220 while continuing the arcuate motion of the arms 224 is acheived by removing a predetermied number of teeth from gear 520 at location 524 and by adding a geneva wheel 540 and pawl 510 to the folder mechanism 500. The arms 224 that SUppOlt the star wheel axles 222 and star wheels 220 are carried through the nonrotational motion portion of the folder mechanism 500 by the engagement of the gene~a wheel 540 with the pawl 510. At the end of the genvea ~vheel stroke, the gear teeth 522 of gear 520 mesh again wit the gear teeth 532 of gear 530 and rotational motion of the star wheel 220 is resumed. Arcuate motion of arm 224 isnever stopped.

In the preferred embodiment, geneva wheel 540 has six faces 542. While six facesare preferred, it is to be understood that any multiple of three would be sufficient to produce the required motion. Pawl 510 is not a traditional pawl in that it does not include pivot and does not aply to racheting motion. Instead the pawl 510 functions like 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 fi~ed 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 ~vorkpiece 12 as it 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 150 in carousel 100 and allows ejector bar 290 to timely eject fully wrapped workpiece 12 between belts 302 and 304 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 brac~eting which is fi~ed to frame 30 The cam 292 is stationary and does not rotate The first end of a connecting 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 ~vhich rides in cam 292 ~Vhen a rotating carousel pocket 150 comes into alignment with the exit conveyor 300, the ejector bar 290 and connecting rod 294 are pushed out-vard by the cam follower 296 ~vhich rides in the cam 292 The wrapped workpiece 12 is ejectedinto exit conveyor 300 between belts 302 and 304 The conveyor belts 302 and 304 carry 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 mechanism 400 can be incorporated into our wrapping machine 10 The gluing mechanism 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 allowed to dry on the wrapping paper 15 prior to the wrapping of the ~vorkpiece 12 After the wrapping paper sheet 18 has been banded about the periphery of the workpiece by the pocket 150, underfolder plate190 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 A second alternative folder mechanism, referred to generally as 600, is shown inFigures 13-28. The folder mechanism 600 produces the most aesthetically pleasingwrap while allowing the wrapping machine 10 to run at its highest speeds and nottear the wrapping paper 18.

Alternative folder mechanism 600 requires its own stuffer mechani~m 720 which varies in both function and structule from those previously disclosed. As best shown in Figures 20 and 28, each stuffer spindle 732, which helps to form the wrap on the side of the ~vork piece 12 and tucks the wrapping paper 18 into the center core 13, is attachecl to a rod 734. The stuffer spindles 732 are actuated by stuffer actuating cam followers 740. Each cam follower 740 is driven by a barrel cam 750having a cam track 752 ~vhich controls ~hen the stuffer spindles 732 are advanced toward or inserted into the work piece center tube 13 and when the stuffer spindles 732 are retracted from the work piece center tube 13. The upper portion of the barrel cam 750 is sho~vn laid flat in Figure 19. Figure 24 sho~vs the timing of the barrel cam 750 upper portion including its dwell portion, inward portion, seconddwell portion, withdraw portion, third d~rell portion, insert portion, and its second withdraw portion. The entire camed stuffer mechanism 720 is driven by the rotation of the carousel 100. The barrel cam 750 is attached to the wrapping machine frame 30 and is located parallel and adjacent the carousel 100 as previously disclosed. The diameter of the entire barrel cam 750 is appro~cimately the same as the diameter of the carousel 100.

After the wrapping paper 18 is fully banded around the outer circumference of the work piece 12, the pair of stuffer spindles 732 approach the work piece 12 and stop a predetermined distance from the work piece center tube 13.

As best shown in Figures 13 and 14, a pair of folder mechanisms 600 are mounted to the rotating carousel 100 adjacent each pocket 150. In other ~vords, a foldermechanism 600 is mounted on each side of rotating carousel 100 at each pocket 150.

Each pair of folder mechanism 600 is driven by a crimper cam 610 that is mountedto the wrapping machine frame 30. The cam 610 is shown in Figure 25. The cam 610 is stationary and does not rotate with the carousel 100. Within the cam 610 are located a plurality of cam followers 612. The number of cam followers 612 is thesame as the number of pockets 150 on the rotating carousel 100.

Referring to Figure 13, a lever plate 620 is mounted on the side of the rotatingcarousel 100. A crimper frame 630 is attached to each side of the carousel 100. The lever plate 620 is mounted to the carousel 100. Each crimper frame 630 extends from the lever plate 620 toward the corresponding pocket 150 and is rigidly connected to the lever plate 620. A is substantiall~ "L" shaped activating arm 640 includes a first end 642, a second end 644, and an apex 646. Apex 646 is pivotally connected to lever plate 620 by means of a pivot shaft 6~0. The cam follower 612 is mounted to first end 642. As cam follower 612 moves in cam 610, activating arm G~0 pivots at pivot shaft 650 and second end 644 of activating arm 640 moves in an arc around shaft pivot 650.

Again referring to Figure 13, the folder mechanism 600 of the preferredembodiment further includes three pairs of folding or crimping fingers 660, 670, and 680. For purposes of clarity in figures 13 and 14, each finger is sho~ n in a different line thickness. The geometry of each finger is shown in Figures 15 through 17. As shown in Figure 15, finger 660 includes an aperture 662 and a slot 664. As shownin Figure 16, finger 670 includes apertures 672, 674, and 676. As shown in Figure 17, finger 680 includes apertures 682 and slot 684. Referring to Figure 18, the arrangement of the three pairs 660,670, and 680 ~vith respect to rotating carousel 100 and a typical ~vork piece 12 can be seen.

Referring back to Figure 13, finger 660 is pivotally connected to second end 644 of activating arm 640 at aperture 662. A first slide block and pivot pin 690 is fixedly connected to crimper plate 630 at 632. The slide block 690 is received within finger slot 664.

Near second end 644 of activating arm 640, an offset arm 700 is attached. A
connecting link 710 has its first end 712 connected to the end of offset arm 700 that projects away from second end 644 of activating arm 640. The opposite end 714Of connecting link 710 is pivotally attached to aperture 672 of finger 670. Aperture 674 of finger 670 is pivotally connected to crimper frame 630 at 634. A second slide block and pivot pin 692 is connected to aperture 676 of finger 670. Finger 680 is incorporated into the folder mechanism 600 by its aperture 682 being pivotally connected to pivot pin 690 and its elongated slot 684 receiving slide block 692.
Thus, fingers 660, 670, and 680 work in unison as follows. As cam follower 612 rides in cam 610, activating arm 640 pivots about pivot shaft 650. ~Vhen pivoted, second end 644 of activating arm 640 moves in an arc about pivot point 650. Thismovement in turn causes finger 660 to move in an arc to-vard pocket 150 around pivot point 690. Simultaneously, finger 670 is pivoted around aperture 674 toward pocl;et 150 at point 634 by means of connecting link 710. Still simultaneously, finger 680 moves in an arc about pin 632 also toward pocl;et 150. Figure 14 shows the fingers 660, 670, and 680 in the full~ closed position.

~Vhen the stuffer spindles 732 have moved to the predetermined distance from thework piece 12, the three pairs of fingers, 660, 670, and 680 on each side of the work piece 12 begin to close; i.e. move from the position shown in Figure 13 to the position shown in Figure 14. The stuffer spindle 732 initially acts as a mandrel to prevent the ends of the wrapping paper 18 from collapsing toward the worl; piece 12 end. As the three pairs of fingers 660, 670, and 680 continue to close on each side of the worl; piece 12, each stuffer spindle 732 is withdrawn. If each stuffer spindle 732 was not withdrawn, the fingers 660, 670, and 680 would close into the spindle 732.

After the three pairs of fingers 660, 670, and 680 have reached their fully closed position as shown in Figure 14, the fingers 660, 670, and 680 open and return totheir position as shown in Figure 13. The three pairs of fingers 660, 670, and 680 form a column-like structure 760 of wrapping paper as sho-vn in Figure 22. The column terminates at end 762.

As the fingers reopen, stuffer spindles 732 reapproach the ends of ~ ork piece 12.
Each stuffer spindle 732 includes an opening 733 in its end as sho- n in Figures 21 and 22. The tip 762 of the column-like wrapping paper end structure enters the opening 733 as the spindle 732 continues to approach the worl; piece 12. The stuffer spindle 732 compresses the wrapping paper 18 against the side of the work piece 12 and tucks the top end portion 762 into the center tube 13 as shown in Figure 23. The stuffer spindle causes the wrapping paper 18 to fill the diameter of the center tube 13.

Referring to Figures 20 and 28, the force of the stuffer spindles 732 which enters center tube 13 of work piece 12 is limited by a spring 742 which is mounted about each spindle rod 734. The cam follower 740 which rides in barrel cam 750 is mounted to a bearing block 744. The bearing block 744 rides on parallel rods 736.
As shown in Figures 20 and 28, the spring 742 is positioned between bearing block 744 and collar 746 which is fixed to rod 734. When the barrel cam 760 and cam follower 740 system push the stuffer spindle 732 and a portion of the wrapping paper into the center of the tube 13 of ~vork piece 12, resistance may be encountered as the stuffer spindle 732 pushes the gathered or conical portion 762 of wrapping paper 18 into center tube 13. When this occurs, spring 742 compresses between bearing block 744 and collar 746. Thus, the stuffing pressure of the stuffer spindles 732 is limited to the compression rate of the spring 742.

Claims (29)

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 armend 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 pivotallymounted to the carousel mechanism;

the geneva wheel assembly rotating the star wheel and pivoting the star wheel onthe 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 firstsheave;
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 approachingthe 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 lowerbelts 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 substantiallyparallel sides of the workpiece;
ejecting the workpiece from the pocket.

17. An apparatus for wrapping work pieces, 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 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 mechanism mounted to the carousel mechanism adjacent each wrapping station.

18. The apparatus of claim 17, wherein said folder mechanism comprises:
a lever plate, said lever plate attached to said frame structure;
a crimper frame, said crimper frame coupled to said lever plate;
an arm structure, said arm structure pivotally coupled to said crimper frame andsaid lever plate;
a connecting link having a first end and a second end;
said first end of said connecting link coupled to said arm structure;
a finger mechanism, said finger mechanism coupled to said crimper frame;
said second end of said connecting link coupled to said finger mechanism.

19. The apparatus of claim 18 wherein said arm structure comprises:
an activating arm having a first end, a second end, and an apex;
said apex of said activating arm coupled to said lever plate;
said second end of said activating arm coupled to said finger mechanism;
an offset arm having a first end and a second end;
said first end of said offset arm coupled to said activating arm;
said second end of said offset arm coupled to said first end of said connecting link;
said first end of said activating arm having a cam follower;
said cam follower engaged within a cam.

20. The apparatus of claim 19, wherein said apex of said activating arm is coupled to said crimper frame and said lever plate by means of a pivot shaft.

21. The apparatus of claim 18, wherein said finger mechanism comprises:
a first pair of fingers having a first end, a second end, a first slide block, and a longitudinal opening formed therein;
said first end of said first pair of fingers pivotally connected to said second end of said activating arm;
a second pair of fingers having a first end, a second end, a midsection, and an aperture formed therein;
said first end of said second pair of fingers coupled to said second end of saidconnecting link;
said midsection of said second pair of fingers pivotally connected to said crimper frame;
a third pair of fingers having a first end, a second end, a second slide block, an aperture formed therein, and a longitudinal opening formed therein;
said first slide block of said first pair of fingers rides within said longitudinal opening of said first pair of fingers and within said aperture of said third pair of fingers;
said second slide block rides within said longitudinal opening of said third pair of fingers and within said aperture of said second pair of fingers.

22. The apparatus of claim 17, wherein said stuffer mechanism comprises:
a barrel cam, said barrel cam mounted to the frame structure;
a cam follower structure, said cam follower structure located within said barrelcam;
a stuffer spindle having an opening formed therein;
a stuffer rod having a first end and a second end;
said first end of said stuffer rod coupled to said stuffer spindle;
said second end of said stuffer rod coupled to said cam follower structure.

23. The apparatus of claim 22, wherein said stuffer mechanism further comprises:
a spring having a first end and a second end;
said stuffer rod having a collar;
said first end of said spring coupled to said collar of said stuffer rod;
said second end of said spring coupled to said cam follower structure.

24. The apparatus of claim 22, wherein said cam follower structure comprises abearing block having a cam follower engaged within said barrel cam, said bearingblock coupled to said second end of said stuffer rod.

25. The apparatus of claim 17, wherein each of said work pieces includes:
a center tube;
a sheet of wrapping paper banded about each of said work pieces;
said sheet of wrapping paper having two ends extending outwardly a predetermineddistance beyond said work piece;
said finger mechanism engages said ends of said sheet of wrapping paper forming a paper column structure; and said paper column structure enters said opening formed within said stuffer spindle, said stuffer spindle compressing said paper column structure into said center tube of said work pieces.

26. The apparatus of claim 17 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 armend 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.

27. The apparatus of claim 17 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.

28. The apparatus of claim 17 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.

29. The apparatus of claim 17 further including an infeed conveyor connected to the frame,