US20060254214A1

US20060254214A1 - Apparatus and method for binding a load with tape

Info

Publication number: US20060254214A1
Application number: US11/443,559
Authority: US
Inventors: Bruce Cox; David Wakefield
Original assignee: Individual
Current assignee: Safetech Pty Ltd
Priority date: 2000-10-09
Filing date: 2006-05-31
Publication date: 2006-11-16
Also published as: US20040031238A1; US7114308B2; AUPR063700A0; WO2002030751A1

Abstract

An apparatus for binding a three-dimensional load with tape comprises a turntable for rotating the load, a tape dispenser and a logistical controller. The tape dispenser is moveable relative to the turntable and the load. The detector detects the top of the load, and is moveable with the tape dispenser. The logistical controller is arranged to control rotation of the load and movement of the tape dispenser. In particular, the controller is arranged to operate the apparatus to dispense the tape according to a predetermined default pattern until the detector determines the top of the load. Once the tope of load is detected, the controller is arranged to operate the apparatus according to a corrected pattern based upon the detected top of load. Further, the controller may comprise a computer program which calculates the required turntable speed for a substantially constant predetermined speed of the carriage such that the relative position of the turntable and the carriage is such that the load is bound according to the default pattern or the corrected pattern.

Description

RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. Ser. No. 10/398675 entitled “Method and apparatus for wrapping a load”.

FIELD OF THE INVENTION

The present invention relates to an apparatus and method for binding a load with tape. In particular, although not exclusively, the invention relates to a tape binding apparatus of the type in which a palletised load to be secured is rotated on a turntable and the tape is dispensed from a tape dispenser which moves up and down on an upright mast alongside the rotating load to dispense the tape in particular patterns over the load.

BACKGROUND OF THE INVENTION

Conventionally, stretch film is used to wrap a palletised load. The load is supported on a turntable and the stretch film is dispensed from a roll of film which resides on a moveable carriage which moves up and down alongside the palletised load. The carriage advances so that the film is dispensed in a spiral. The pitch of the spiral is such that the edges of the film overlap the previous layer. The carriage includes a photoeye so that as it advances upwards, the photoeye detects the top of the load so that after a brief delay, the carriage will then commence to move downwards. Since the pitch is chosen to enable the film to overlap, the sides of the load will be completely enshrouded in the stretch film at the completion of one upward and downward pass of the stretch film.
Stretch film has inherent drawbacks in that there is considerable wastage of material since at the destination of the load, the film is simply cut from the load and is not reused. Another drawback in the use of stretch film is that some products once palletised need to breathe to allow cooling and avoid condensation or sweating. This can lead to double handling of the loaded pallets or loss of product from a pallet before wrapping.
Tape dispensers have become known which apply an adhesive tape which is stretchable to maintain tension in the tape. The adhesiveness tends to diminish as the tape is stretched. The tape can be applied to the load by rotating the load on a turntable and dispensing the tape from a moveable carriage which moves up and down alongside the load. Unlike stretch film, the carriage moves up and down more than once, usually about four times up and down to produce a pattern of crisscrossing upward and downward helixes. However, unlike stretch film wrapping which enshrouds the load, the tape must be applied with precision so that the resulting tape pattern will effectively secure the load. The tape pattern may be dependent upon the dimensions of the particular items in the load as is described in our earlier application (Ser. No. 10/398675), from which the present application is a continuation-in-part. The contents of the earlier application Ser. No. 10/398675 are incorporated herein by reference.
Therefore, in order to effectively bind a load with tape, a precise pattern must be adhered to and accordingly, the overall dimensions of the load are known in advance to produce the precise pattern. Thus, with existing tape binding apparatus, the operator is required to key in the height of the load and for this he will likely need to use a tape measure. Additionally, the operator will be required to enter an “X” value which equates to the number of sides the load is rotated through for the inclined tape paths to traverse from the bottom to the top. Also, in the completed pattern, the “X” number will equate to the number of crosses formed in tape on each side of the load. This entry of data, especially the measuring step is time consuming.
Another issue for existing tape binding apparatus is that it is relatively slow in comparison to conventional stretch film wrapping apparatus. One of the reasons for this is that the tape dispensing carriage needs to traverse up and down at least four times in order to create the desired binding pattern. In contrast, stretch film wrappers only need to traverse up and down once. Furthermore, in binding a palletised load which is generally rectangular or square in cross-section, the carriage will generally pause to wait for the turntable to rotate to present each side of the load to which tape is to be applied. This also slows down the tape binding process. There are limits to which the carriage can be moved, firstly, for reasons of operator safety. Secondly, the carriage needs to change direction a number of times and there is therefore a maximum speed that the carriage can travel in order to decelerate within a reasonable time and distance.
Another particular problem encountered by tape binding apparatus which is not so problematic with film wrappers is that of partial top layers on a pallet. With stretch film wrapping, partial layers are easily dealt with since the stretch film can still cocoon around the partial layer. However, a partial layer is not so easily handled with a relatively thin piece of tape.
It is therefore an object of the present invention to overcome at least some of the aforementioned problems.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the present invention there is provided an apparatus for binding a three-dimensional load with tape, the apparatus comprising:
a turntable for supporting and rotating the three-dimensional load;
a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load;
a logistical controller arranged to control rotation of the load and movement of the tape dispenser; and
a detector to detect the top of the load, the detector being moveable with the tape dispenser, wherein the controller is arranged to operate the apparatus to dispense the tape according to a predetermined default pattern until the detector determines the top of the load, whereafter, the controller is responsive to a signal from the detector corresponding to the detected top of load to operate the apparatus according to a corrected pattern based upon the detected top of load.
The detector may be in the form of an electronic light detector which detects reflected light. The detector may include a light source and may detect reflected light from the load. Alternatively, the detector may detect reflected light from a spaced sensor. The light source may be infra-red or laser. The detector is not limited to an electronic light detector and may be any other kind of known limit detector.
The detector is moveable with the tape dispenser. Accordingly, if the tape dispenser is provided on a moveable carriage driven up and down a mast, then the detector may be mounted on the carriage. Preferably, the detector is spaced above the taped dispenser and as such, provides advance warning to the controller that the tape is approaching the top of the load.
A typical pattern which may be applied to the load is a helical pattern where the tape dispenser moves up and down relative to the load as the turntable is driven to rotate. Accordingly, the tape travels in an upward continuous helix and then a downward continuous helix. Additionally, substantially level passes of the tape may be applied to the load subsequent to each upward traverse and also subsequent to each downward traverse.
In the abovementioned exemplary pattern, the controller operates the apparatus to dispense the tape in the predetermined default pattern by selecting a default pitch. The dimension of pitch is the vertical distance between the ends of the tape on one side of the load. In a preferred form of the invention, the controller operates the apparatus to initially dispense tape to create an upward helix on the load. The tape is applied at a default pitch until the detector determines that the top of the load has been reached. Once the controller is aware of the dimensions of the load, the controller then operates the apparatus according to a corrected pattern. In the exemplary helical pattern described above, the tape will be applied to a portion of the load between a user defined upper or lower limit. To apply the corrected pattern, a corrected pitch is calculated so that the tape will be applied to a whole number of side of the load as it traverses between the upper and lower limit and vice versa.
While it has been described above that the exemplary helical pattern may commence with an upward helix, this need not be the case. The pattern may commence intermediate the height of the load and first helix down before winding back up. This particular variation may enable the tape to commence at a convenient height for the user to save the user having to bend down to apply the tape to the load.
The pattern applied to the load is not limited to the exemplary helical pattern described above and other patterns may be applied to the load. For example the helixes need not be continuous and one or more horizontal bands may be applied during the upward or downward traverse of the tape. Furthermore, looping over the top of the load between the upward and downward traverse is also included within the scope of the invention.
The controller may receive a number of user inputs through the use of a keypad or other data entry means. The tape need not be applied to the whole of the load and in fact the top limit of the tape is generally spaced below the top of the load. In the looping example, there may be a top limit of the helical pattern with still looping over the top of the load. Furthermore, the tape may be applied to the pallet which supports the load. Accordingly, the pattern between these upper and lower limits may be referred to as the pattern array. The user may input into the controller the upper limit of the pattern array and the lower limit of the pattern array. The user may input the upper limit by entering a value of top drop which is defined as the distance from the top of the load. This avoids the need to measure the overall load height.
The user may also input the pallet dimensions. It is also possible for the user to enter a variation into the calculated pattern. For example in the above described helical pattern there is a whole number of crosses applied to each side of the load and the default number of crosses (X value) is determined by the controller. Accordingly, the user can input a variation to increase or decrease the number of crosses on each side of the load, by way of a whole number. The user may also input a maximum turntable speed.
The turntable may be driven by a motor and the carriage may be driven by another motor. The controller controls operation of both the turntable motor and the carriage motor. Feedback may be provided to the controller as to the turntable orientation. Feedback may also be provided as to the height of the carriage. For example, feedback may be provided by a detector determining the passing of teeth of a toothed wheel.
The controller is able to calculate the array height by determining the carriage height when the top of the load is detected. There may be an adjustment for the offset between the carriage height and the actual location of the detector. From this, the lower limit dimension and the top drop are deducted to obtain the array height. The corrected pattern is then based on the array height.
By way of example, in the helical pattern, the number of crosses is calculated by dividing the array height by the default pitch and rounding this to the nearest whole number to arrive at a value for the number of crosses (X value). The corrected pitch is then calculated by dividing the array height by the X value.
As previously mentioned, the detector will provide advance warning that the tape is approaching the top of the load. Accordingly, the controller may determine an adjustment which is required so that the tape reaches the upper limit coinciding with the end of an inclined pass across a side of the load.
In accordance with the second aspect of the present invention there is provided a method of binding a three-dimensional load with tape, the method comprising:

a) binding the load with tape dispensed from a movable tape dispenser according to a default pattern;
b) detecting the top of the load by a detector moveable with the tape dispenser during step a); and
c) binding the load with a corrected pattern based on the detected top of load.

The above method is preferably carried out in a tape binding apparatus, the operation of which is controlled by a controller. The tape binding apparatus may include a turntable to rotate the load and a vertically moveable carriage on which the tape dispenser is provided. The controller may control the turntable and the carriage speed to effectively wrap the load. The controller may access stored default pattern parameters for operating the apparatus according to the default pattern. The controller may also receive a signal from the detector corresponding to the top of load. The controller then uses this received information to calculate the height of the array i.e. the portion of the load intended to be bound and then operates the apparatus according to a corrected pattern. Any of the features described above in connection with the first aspect may be applied to the second aspect of the invention.
In accordance with a third aspect of the present invention there is provided an apparatus for binding a load with tape, the apparatus comprising:

a turntable to rotate the load;
a carriage to carry a tape dispenser for movement along an upward path and a downward path adjacent the load;
a controller to control the movement of the turntable and the carriage to bind the load according to a desired pattern, wherein the controller comprises a computer program which calculates the required turntable speed for a substantially constant predetermined speed of the carriage over a substantial portion of the upward path or a substantial portion of the downward path such that the relative position of the turntable and the carriage is such that the load is bound according to the desired pattern.

The desired pattern may be one which is predetermined i.e. it may be a default pattern. Alternatively, the desired pattern may be one which is calculated during the binding sequence i.e. once the top of the load is detected, as with the first aspect of the invention.
It will be appreciated that in the upward path of the carriage, while the turntable rotates, the tape will be applied in an upward helix to the load. Similarly in the downward path of the carriage, while the turntable continues to rotate in the same direction, the tape will be applied in a downward helix onto the load. The carriage speed may be constant over a substantial portion of both of these paths. Preferably, the speed of the carriage is constant over an intermediate portion of the paths which allows for acceleration and deceleration at the extremes of the paths. Furthermore, the carriage may have two possible constant speeds being a fast speed and a slow speed. The slow speed may be used to apply the default pattern as described in connection with the first aspect of the invention. The fast speed may be used to apply the corrected pattern.
The turntable may be driven by a variable speed drive which may be infinitely variable up to a maximum speed which will either be determined by the parameters of the drive or may be determined by a user input into the controller. The controller may provide an analog output to the variable speed drive.
A digital output may be provided from the controller to the carriage drive. The digital signals may be one of up, down or fast.
In a preferred embodiment of the invention, the load intended to be bound will be square or rectangular. The controller may be adapted to receive user inputs of the dimensions i.e. length and width. Accordingly, the desired pattern for the tape may be broken down into quarter turn segments. In this manner the computer program may calculate, for the next quarter turn of the turntable, where the carriage is required to apply tape according to the desired pattern and when the carriage will arrive at a particular position given the constant speed and then calculates the speed of the turntable required to rotate the load through the quarter turn.
The desired pattern may not be limited to a helix up and helix down and additionally may incorporate other features including looping, banding and an initial home position as described above in accordance with the first aspect of the present invention. In particular, the step of looping takes place between the upward path and the downward path by the tape crossing over the top of the load at the corner instead of traversing the corner at the sides of the load. This provides additionally securement at the top of the load. Additionally, where the load is provided with a sheet of flexible plastic or board at the top of the load, the looping can be used to secure this sheet.
The feature of looping may be an operator selected option which the operator may select through a key pad, this option being conveyed to the controller. Once the looping option is selected, it is applied between each upward path and downward path in the binding sequence.
The operator may also adjust the parameters of the looping. For example, the operator may be able to adjust the overshoot. This is the distance above the top of the load to which the carriage travels to apply the tape in a loop over the corner. A high overshoot will create a loop which is more greatly spaced from the corner than a loop resulting from a low overshoot.
In looping, the carriage still travels at a constant predetermined speed and the computer calculates the required turntable speed for the turntable to be in the correct position at the conclusion of the carriage overshoot. In practice, this may result in the turntable speed being quite slow.
In accordance with the fourth aspect of the present invention there is provided an apparatus for binding a load with tape, the apparatus comprising:

a turntable for supporting and rotating the three-dimensional load;
a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load; and
a logistical controller arranged to control rotation of the load and movement of the tape dispenser; wherein the controller is arranged to operate the apparatus to dispense the tape according to a desired pattern comprising a plurality of helical paths, each path including at least one upward helix, a loop over the top of the load and a downward helix giving rise to a pattern whereby the upward and downward helixes are transversely spaced from each other and each upward helix crosses with at least one downward helix.

The controller may be operated in such a way that the looping is conducted in the manner described above in connection with the third aspect of the invention.
The operator may be able to input an overshoot parameter into the controller to affect the looping characteristics. An invention may also reside in a method of binding a load with tape so as to effect looping over the top of the load.
In accordance with the fifth aspect of the present invention there is provided an apparatus for binding a three-dimensional load with tape, the apparatus comprising a turntable for supporting and rotating the three-dimensional load; a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load; and a logistical controller arranged to control rotation of the load and movement of the tape dispenser, wherein the logistical controller controls the operation of the apparatus to bind the load with tape according to a desired pattern; and means for inputting into the logistical controller, one or more values corresponding to one or more selected heights, wherein the logistical controller controls the operation of the apparatus to apply substantially horizontal over-bands over the desired pattern at the one or more selected heights.
The invention may incorporate any of the features described above in accordance with the above aspects of the invention. In particular, the desired pattern may be the helical pattern described above which is applied to the substantially the full extent of the load and may optionally include looping. The benefit of the over-banding is that the underlying tape of the helical pattern may be cut down to the uppermost over-band and that portion of the tape removed. The over-banding retains the remainder of the tape binding in place so that a portion of the load may be removed. This makes it possible to load onto a single pallet, boxes or items which are intended for different destinations. If there are three destinations then two over-bands may be applied. The underlying tape of the helical pattern is removed down to the first over-band at the first location. At the second location, the first over-band is removed and the tape of the helical pattern is cut to a level above the second over-band. At the third location, all of the tape may be cut to deliver the remainder of the load.
An invention may also reside in a method of binding a load in a manner which produces overbands.
In accordance with a sixth aspect of the present invention there is provided an apparatus for binding a three-dimensional load with tape, the apparatus comprising:

a turntable for supporting and rotating the three-dimensional load;
a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load; and
a logistical controller arranged to control rotation of the load and movement of the tape dispenser to dispense tape onto the load in a desired pattern, wherein the controller is programmed to position the tape dispenser at a home position which is at a convenient height for the user to position tape on the load and wherein the controller is arranged to control movement of the tape dispenser to a start position to commence application of tape to the load in the desired pattern.

The above aspect of the invention may incorporate any of the features described in the above aspects.

BRIEF DESCRIPTION OF THE DRAWINGS

To facilitate an understanding of the invention, reference is made in the description to the accompanying drawings where the invention is illustrated in several preferred embodiments. It is to be understood, however, that the invention is not limited to the preferred embodiments illustrated in these embodiments.
In the drawings:
FIG. 1 is a plan view of a tape binding apparatus according to a first embodiment of the invention;
FIG. 2 is a side view of the tape binding apparatus shown in FIG. 1;
FIG. 3 is a detailed sectional plan view showing various components of the turntable and a drive means for driving the turntable of the tape binding apparatus of FIG. 1;
FIG. 4 is a side sectional view of the turntable shown in FIG. 3;
FIG. 5 is a side view of a mast assembly together with a carriage assembly and tape dispenser of the tape binding apparatus shown in FIG. 1;
FIG. 6 is an end view of the tape binding apparatus shown in FIG. 5;
FIG. 7 is a plan view of the tape binding apparatus shown in FIG. 5;
FIGS. 8 to 10 are enlarged views of FIGS. 5 to 7 respectively;
FIG. 11 is a schematic diagram illustrating various functional components of a control system for controlling the operation of the tape binding apparatus shown in FIGS. 1 to 10;
FIG. 12 is a side view of the mast assembly and a load supported on the turntable showing attachment of the tape to the load;
FIGS. 13 and 14 are a flow chart illustrating steps performed by the control system shown in FIG. 11 to control operation of the tape binding system shown in FIGS. 1 to 10;
FIGS. 15 to 20 show exemplary loads when bound with various tape binding patterns by the tape binding system shown in FIGS. 1 to 10;
FIGS. 21 and 22 provide various views of each of the sides of a load as it is bound by tape from the tape binding apparatus shown in FIGS. 1 to 10;
FIG. 23 is a schematic view of a modified form of a tape binding apparatus;
FIGS. 24 and 25 provide various diagrammatic views of each of the sides of a load as it is bound with tape with the tape binding apparatus of FIG. 23;
FIGS. 26 a and 26 b are diagrammatic views of two adjacent sides of the load illustrating placement of the tape in looping over the top of the load;
FIG. 26 c is a plan view of the load of FIGS. 26 a and 26 b;
FIGS. 27 a and 27 b are diagrammatic views of two adjacent sides of a load with a variation in the looping over the top of the loads;
FIG. 27 c is a plan view of the load of FIGS. 27 a and 27 b;
FIGS. 28 and 29 are various diagrammatic views of each of the sides of a load as it is bound by tape using the step of looping;
FIG. 30 is a perspective view of a load which is bound with tape with the additional feature of overbanding.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring to FIGS. 1 to 4, there is shown generally an apparatus 2 for palletising and binding a load 18. The apparatus 2 comprises a turntable 4, a mast 8 extending vertically from and connected to a base plate 10, a carriage assembly 12 supported on the mast 8 for vertical reciprocating motion with respect to mast. Carriage assembly 12 includes an arm assembly 14 and a roll mounting assembly 16 which supports a roll of tape 80 to be dispensed therefrom and wound around the load 18 located on the turntable 4. The arm assembly 14, roll mounting assembly 16 and roll 17 form part of a tape dispensing arrangement 13 for applying tape to the load 18. Both the arm assembly 14 and the roll mounting assembly 16 may be integrally formed with the carriage assembly 12 or connected directed to the carriage assembly 12. A pre-tensioning assembly 20 is connected to the carriage assembly 12, and acts to pre-tension the tape dispensed from the tape dispensing means 13. The tape is preferably #8884 or #8886 manufactured by Minnesota Mining & Manufacturing (3 M) Company, or tape as disclosed in the specification of U.S. Pat. No. 5,496,599 in the name of 3 M. Details a pre-tensioning assembly 20 are disclosed in our earlier application Ser. No. 10/398675.
The turntable 4 is adapted for rotational movement about a central hub 24. The turntable 4 includes a top plate and a bottom plate. Located between the top and bottom plates is a belt 28 which drives a pulley 26. The belt 28 is driven by a drive wheel/pulley 30 driven by an electric motor 32, or other turntable drive means. In an alternative embodiment, the pulley may comprise a circular sprocket 26 which has teeth adapted to engage an endless drive chain 28 which passes around a sprocket 26.
Referring to FIGS. 5 to 10, the vertical reciprocating motion of the carriage assembly 12 is enabled by a sprocket and pulley arrangement mounted at opposing ends of the mast 8. A drive chain 42 is attached to part of the carriage assembly 12. An electric motor 44 or other carriage assembly drive means causes the rotational movement of a drive sprocket 46 located at a lower end of the mast 8 by means of drive shaft 48. A pulley 50 is mounted to the upper end of the mast 8. Alternately, the pulley 50 may be replaced by a sprocket which includes teeth to engage the chain 42.
The carriage assembly 12 includes a carriage tube 52 adapted to fit around the periphery of the mast 8 to enable slidable movement therealong. The movement of the carriage assembly 12 along the mast 80 is enabled by connection of the drive chain 42 to the carriage tube 52 by way of suitable connection such as depending lugs or flanges 54 and 56 located on the outer surface of the carriage tube 52.
The movement of the carriage assembly 12 vertically up and down the mast 8, in conjunction with the rotation of the turntable 4, enables the tape 80 to be wound around the palletised load 18 in a helical or circular manner. Particular patterns of the helical/circular binding are able to be applied to the load 18 by controlling the rotational movement of the turntable 4 and the movement and position of the carriage assembly on the mast 8.
A control panel structure 67, shown in FIG. 2, is connected to the mast assembly 8 for attachment of an electronic circuit board and a display 68. Electric cables run to and from the circuit board 68 and from sensors 60, located near the toothed wheel 62, and 64 located near the toothed wheel 66. The toothed wheel 60 is mounted to the turntable 4 about the central hub 24, whilst the toothed wheel 66 is mounted about the shaft of the motor 44. The sensor 60 is mounted adjacent the toothed wheel 62 to sense the number of teeth of the toothed wheel passing in front of the sensor to thereby provide an indication of the angular position or rotation of the turntable 4. The sensor 64 is mounted adjacent the toothed wheel 66 in order to sense the number of teeth passing on the toothed wheel 66 before the sensor 64 in order to indicate the displacement of the carriage assembly 12 along the mast 8.
The sensors 60 and 64, and corresponding toothed wheels 62 and 66 form part of a control system 100 for controlling the rotation of the turntable 4 and the movement of the carriage assembly up and down the mast 8, to thereby control the binding process of the palletised load 18.
As can be seen in FIG. 11, the sensors 60 and 64 form part of a control system 100 for controlling operation of the motors 32 and 44. Power is supplied from the mains supply 102 to a Variable Frequency Drive (VFD) 106 adapted to drive the motor 44 controlling carriage assembly movement, and VFD 106 driving the motor 32 controlling turntable rotation. Power is also supplied to carriage drive 104. The VFD 104 and 106 are supplied with 240 volts AC from the mains supply 102.
A controller 108 is supplied with 12 volts DC from the mains supply 102 through a transformer 110. The controller 108 is housed in the control panel structure 67 attached to the mast assembly 8. Control signals are sent from the controller 108 to the control signal input terminals of the VFDs 104 and 106 in accordance with instructions fetched from the PROM 112 storing a computer program. The control signals supplied by the controller 108 are dependent upon the output signals of the sensors 60 and 64, which are supplied to the controller 108. A keypad 114 is provided to enable the entry of data by the operator, whilst a display 116 and other associated indicators display selected information to the operator.
Typically, the keypad 114 and display 116 are accessible through the panel 68 shown in FIG. 2.
Each of the sensors 60 and 64 is adapted to transmit a pulse every time a tooth, respectively of toothed wheels 62 and 66, passes in front of the sensor. The number of pulses that must be received by the controller 108 from the sensor 60 to correspond to a 90° rotation of the turntable 4 is pre-stored in the controller 108 so that when an internal counter reaches that number of pulses, the controller is able to detect a quarter turn rotation of the turntable 4. Similarly, the movement of the carriage assembly 12 up and down the mast 8 and the number of pulses emitted by the sensor 64 are calibrated that by counting the number of pulses received from the sensor 64 the controller 108 is able to determine the distance travelled along the mast.
In FIG. 12 there is shown a side view of the load 18 supported by a pallet 23. The pallet and load are mounted on the turntable 4. In this example, the load 8 includes 4 layers 19, each consisting of a series of sixteen containers 21.
The length of the load 18 is a fixed distance L_p, whilst the distance from the rear of the load 18 to the point on the tape dispensing means 20 from which the tape is dispensed is also a fixed distance L_c. In this example, a pattern of tape is intended to be applied to the load 18, with the tape 80 running between points 25 half way along the height of each box 21. In the position shown in FIG. 12, it is desired for the tape 80 to run from a point halfway up the corner of the left most container of the lower layer of the load 18 to a point halfway up the corner of the container the second lowermost layer. The vertical distance between points 25 is referred to as “pitch”.
The controller 108 may be programmed with data corresponding to the various distances L_pand L_cand the pitch H_b. However, it is preferred that the operator will enter certain dimensions which include the pallet dimensions of length L_pand breadth (not shown) and height H_l. However, it is more common practice that the operator enters a value of “top drop”. Top drop T_dis the distance from the top of the load down to the point which the operator wants to be the uppermost limit of the tape. In this example, that would correspond to the distance from the top of load 18 down to the point 25 in the uppermost layer. Generally, the dimension of top drop corresponds to half the height of the top layer. The operator may also enter the minimum tape height which is the height from the bottom of the load to the lowest run of tape H_min(see FIG. 15) although a default value may be provided. The operator may also enter the height of the load and an X value which equates with the number of crosses made on each side of the load or alternatively equates with the number of sides of the load to be presented for the tape to traverse from H_minto reach the upper limit defined by top drop.
Thus, the controller 108 can calculate from the entered values of load height, top drop and minimum tape height, a value of array height A (see FIG. 15) which is the height of the portion of the load to be bound with tape. By dividing this value by the X value, the controller can determine the pitch H_b. Generally speaking, the distance L_cwill be already programmed and not necessary to be entered by the operator. Instead of entering the X value, the operator may simply enter the number of layers in the load. Alternatively, the operator need not enter an X value or the number of layers, instead, the controller could calculate a pitch from the array height and the dimension of top drop.
Alternatively, the operator could enter the height of each layer and the number of layers. From this, a load height can be determined (assuming a default pallet size). A default top drop based on half the height of each layer could thus be used to determine array height. Thus determination of pitch could be made on the information about the height of each layer, given the desirability of crossing points 25 midway along the height of each layer.
Thus, the characteristics of the load may be entered into the controller through the keypad using various different aspects of the load including height of the load, top drop, height of each layer, number of layers, pallet dimensions of length and breadth, desired number of crosses (X value). Which characteristics are required to be entered by the keypad will depend upon the particular programming of the apparatus. There is not one particular combination of parameters which are essential to the invention.
Additionally, the controller may be programmed with a number of default values including L_c, H_min, pallet size. The controller may use these default values or there may be a manual override for values entered from the keypad. From the default values and/or the operator entered values, the parameters of the binding pattern can be determined by the controller.
From the data corresponding to the distances L_p, L_cand H_b, the controller 108 is able to determine the distance H_cthrough which the tape dispensing apparatus must travel for the tape to be inclined at pitch H_bacross each side of the load. In the exemplary arrangement shown in FIG. 12, the load 18 and pallet 23 have four sides, and a predetermined pattern of tape 80 is applied to the load 18 by driving the turntable 4 through a series of 90° rotations, and by driving the carriage assembly 12 up and down the mast 8 to predetermined positions prior to the completion of each of those 90° rotations.
To explain a typical binding sequence, FIGS. 21 and 22 show the entire binding sequence for a four-sided load 500 consisting of two layers 501 and 502 stacked on a pallet 503. The letters A, B, C and D refer to the sides of the load 500. The exemplary load positions referenced 401 to 432 in these Figures demonstrate the manner in which a multiple-X pattern is applied to the load 500 by the tape binding apparatus 2. Initially, the operator from the keypad selects an X value of 2 to be applied to the load 500 and enters the top drop 504 and minimum tape height 505.
Once tape is applied to the load 500 in position S, the turntable is rotated through 90° and the carriage assembly 12 driven so that the tape dispensing means 20 dispenses tape at the minimum tape height 505. Since the X value is 2, the height at which the helixes of tape will cross at the edges of the load 500 will be midway between the top drop and minimum tape heights 504 and 505. In position 402, the carriage assembly is driven so that the tape is dispensed from a position higher than this intermediary X point 506 in order to ensure that tape crosses the corner at the intermediate height 506. In position 403, the load 500 is again rotated and the carriage is driven to a height in order that tape can be applied on face C from the intermediary X point height 506 to the top drop height 504. The carriage will thus overshoot the top drop height 504 to apply tape at top drop height 504.
At position 404, the carriage assembly is driven back down to the top drop height 504 in order to dispense tape horizontally and apply a portion of the top band at the top drop height 504. In position 405, the carriage assembly 12 is driven down the mast 8 to a position below the intermediate X point height 506 in order that tape can be applied on face A from the top drop height 504 to the intermediate X point height 506.
In position 406, the turntable 4 once again rotates and tape is applied between the intermediate X point 506 height and the lower portion of the load 500. In this case, the carriage assembly 12 is unable to be driven so that the tape dispensing means is below the height of the pallet 503 and the tape is only able to be applied at the minimum tape height 505 upon a further rotation of the pallet as shown in position 407. In position 408, the load is rotated a further 90 on the turntable 4 and a portion of a band is applied at the minimum height 505. Positions 409 to 432 illustrate the manner in which the tape is applied to complete the pattern to the load 500. In this pattern, it will be appreciated that tape is applied to the load 18 in a series of spaced upward and downward helixes positioned so that the helixes cross at predetermined locations.
It will be appreciated that having entered data indicative of the pallet and load and optionally certain characteristics of the pattern to be applied to the load and having been programmed with the known physical dimensions of the carriage assembly, tape dispenser and displacement between the mast 8 and the centre of the turntable, the controller 108 is able to operate the motors 32 and 44 in order to apply the tape in a desired pattern to contain the load 500.
FIGS. 13 and 14 illustrate a series of steps that the computer program stored in the PROM 112 causes the controller 108 to undertake in order to apply a pattern to the load 18 such as the pattern described above in connection with FIGS. 22 and 23. At step 200, a program corresponding to a desired pattern is loaded into the PROM 112. At step 202, data corresponding to the load and pallet dimensions, and data defining the characteristics of the particular pattern to be applied to the load, are entered via the keypad 114 or default values are loaded from memory. At step 204, the program is then activated by the operator. At step 206, the controller 108 fetches the first instruction of the computer program. This instruction causes the motor 32 to be activated to drive the turntable sprocket 26 in a clockwise direction. At step 208, the controller counts a predetermined number of pulses from the sensor 60 corresponding to a 90° rotation of the turntable. At step 210, once the 90° rotation of the turntable has occurred, the controller fetches instructions for the second cycle of the program. In this step, the controller again energises the motor 44 to drive the carriage assembly 112 to a desired position along the mast 8, and subsequently causes a second 90° rotation of the turntable 4 to occur by energising the motor 44. Once again, output signals from the sensor 60 and 64 are used to confirm when the 90° rotation has occurred and when the carriage assembly 12 has been displaced to a desired position.
Typically, predefined patterns are applied to the load 18 by binding the tape 80 around two or more faces of the load 18 in a generally upward direction, and then applying the tape to two or more faces of the load 18 in a generally downward direction. Horizontal bands may optionally be applied between the upward and downward application of the tape. Accordingly, at step 212, the controller determines whether more than X cycles have occurred, where X corresponds to the number of sides to which the tape is to be applied in a generally upward direction. Accordingly, at step 112 the controller determines whether more than X cycles have occurred. If not, the turntable 4 is again rotated, and the carriage assembly 12 is driven in the upward or positive direction at step 214, prior to the fetching of the instructions for the next cycle.
However, if more than X cycles have been performed, instructions for the next cycle are fetched at step 216. In order that a horizontal band is applied to an uppermost layer of the load 18, the carriage assembly 12 is not driven, but the turntable 4 is caused to rotate through 90°, as sensed in step 218. At step 220, instructions for the next cycle are fetched. Once again, in order to apply a horizontal band at the uppermost layer of the load 18, the turntable is driven through 90°, as sensed in step 222.
At step 224, instructions are fetched for the following cycle. In this example, these instructions correspond to a first cycle in the application of tape 80 to the load 18 in a generally downward sense. The predetermined pattern to be applied to the load 18 includes X such cycles, and accordingly at step 226, a determination is made as to whether these X cycles have been performed. If not, the carriage assembly 12 is driven down the mast 8 by causing the motor 44 to be driven in the opposite direction. In addition, the motor 33 is caused to drive the turntable 4 through another 90° rotation. Once it has been detected at step 228 that the carriage assembly 12 has been driven down to a desired position and that the turntable 4 has been rotated through 90°, instructions for a subsequent cycle are fetched. The tape is continued to be applied to the load 18 in this manner until a desired predefined pattern has been applied to the load.
Various patterns may be applied to the load 18 as shown in the FIGS. 15 to 20. Different predefined patterns may be applied to the entirety of the load 18. Alternatively different predefined patterns may be applied to separate portions of the load 18. The patterns may simply vary because of the different load parameters entered into the keypad by the operator. Alternatively, different pattern options may be selected by the operator.
Another example of the multiple X pattern shown in FIGS. 21 and 22, is illustrated in FIG. 15. In this embodiment, the helixes cross at the corners of the load at the mid height of the layers. The load 300 includes 4 layers 301 to 304. Each of the corners of each layer 301 to 304 is contained by an “X” formed from the crossing of two portions of tape. Accordingly, each layer is fully contained in this predefined pattern. The X value of this pattern is thus 4. This pattern is an exemplary helical pattern, the characteristics of which are determined by the load parameters entered by the operator through the keypad.
An alternate pattern is shown in FIG. 16. This pattern is referred to by the applicant as “banding”, and enables a series of horizontal bands to be applied around the load 300. The required band heights may be chosen by the operator. In this instance, bands 306 and 307 are applied around the uppermost layer and the second lowermost layer of the load. The controller 108 causes the carriage assembly 12 to be driven between the two positions required to apply the two bands 306 and 307, so that an incline of tape 308 is applied between the bands as the tape fleets up or down between banding levels.
FIG. 17 illustrates another variation to banding, known as “overbanding”. This is an option which may be selected by the operator through the keypad. The pattern of FIG. 17 is applied as per the helical pattern of FIG. 15. At the conclusion of the helical pattern, the overbands are applied over the helical pattern. In FIG. 17, two overbands 500 and 501 are shown. The overband 500 is applied to the layer 304. The overband 501 is applied to the layer 303. It is possible for the operator to select the height of the overbands. The overband 500 is applied initially by an inclined tape path from the conclusion of the helical pattern at H_minup to the desired height. The overband 500 is then applied with the carriage maintained at this height for at least a whole revolution. The second overband 501 is then applied by inclining the tape up ¼ revolution to the required height and making the second overband 501. For the sake of clarity, the inclined tape paths for each quarter revolution to reach the desired heights of the overbands 500, 501 are not shown in FIG. 17.
The benefit of overbanding is that the portions of the tape made according to the default pattern can be cut above the second overband 501. The presence of the overband 501 will mean that the remaining tape wound according to the helical pattern will not unravel. With the tape cut above the second overband 501, the top two layers 301, 302 can be removed. The pallet can then be transported to another location where it is desired to remove the layer 303 from the pallet. To achieve this, the overband 501 may be cut and the tape cut down to above the first overband 500, thus freeing the layer 303 from the tape binding. The load 300 may then be transported to yet another location where all the tape may be cut to remove the lowermost layer 304.
As previously mentioned, an operator can select the X value, namely the number of sides traversed by inclined sections of tape from the minimum tape height to top drop. Unlike the bound load illustrated in FIG. 15, it is sometimes not necessary to place an “X layer” on each layer of containers in a load in order to achieve containment of the load. Light loads or shallow containers may require an “X” only every second or third layer of containers. This is because such a pattern will result in steeper angles on the inclined section of tape. This results in a greater downward force component tending to bind the load to the pallet.
As shown in FIG. 18, a single band of tape, or a top strap, may be applied to the load above the main pallet load to contain items placed on the load as a partial layer. For example, in the last few cartons of a production run there may be insufficient quantities of cartons to make up a full layer. Typically, the top strap is constructed at the start of a pattern sequence. In this way, the load integrity is retained if the partial layer is removed. The top strap option may be selected via the keypad and the top strap height may be input manually via the keypad.
Should the operator wish to apply the banding pattern shown in FIG. 19 to the load 300, the operator selects the banding option through the keypad, and enters the total number bands to be applied to the load 300 as well as the height of each band, and the start and finish height of the tape attachment points. On initialisation, the carriage assembly travels to the start height and stops in order that the operator can manually apply the tape to the load 300. Once applied, the turntable rotates to apply the first band at the top height to the load 300, and then moves to the next band height to apply the second band, the tape fleeting between the first band height and the second band height around the exterior surface of the load 300. The banding process continues until the lower most band is applied to the load.
Another pattern that may be applied to the load 300 is known by the applicant as “looping”. As seen in FIG. 20, in this pattern, tape is applied over the top corners of a load in order to cover or secure each edge of the load. Looping is found to be particularly useful where a number of flat sheets or containers, for example, are stacked and it is difficult to effectively provide multiple patterns to the side faces of the stack flattened boxes. Typically, the looping pattern is applied by the tape in a downward manner and in a sidewards manner to secure the flattened boxes or like stacked items.
FIGS. 28 and 29 more accurately reflect the steps required to achieve a looping pattern. In the example of FIGS. 28 and 29, the X number is three. It can be seen that the process commences as would be expected with a three X pattern up to step 706. However, at step 707, instead of traversing downwardly, the carriage moves to a distance D_oabove the top of the load which is referred to as “overshoot”. This causes the tape to pass over the top of the load, instead of traversing the corner around the two sides C, D. The operator has the opportunity to input a value for overshoot through the keypad. The controller will ask for an overshoot value once the looping option is selected.
FIGS. 26 and 27 show the effect of changing the value of overshoot. In FIG. 26, a smaller overshoot D₁is entered by the operator. The choice of overshoot effects the positions 801 and 802 where the tape crosses between the sides of the load and the top of the load. As can be seen in FIG. 26 c, a smaller overshoot results in a relatively shallow loop.
In FIG. 27, a larger overshoot D₂has been selected which will result in crossing points 803 and 804 producing a deeper loop across the corner as shown in FIG. 27 c.
It will be appreciated that the carriage needs to travel a considerable distance in order that the tape be applied from the top of the load to the crossing point 805 as shown in FIG. 26 b. Thus, if the carriage speed is maintained constant for the duration of the binding pattern, the turntable speed will be relatively slow for this portion of the pattern. The control of the relative turntable and carriage speeds is explained further in conjunction with FIG. 23.
FIG. 23 shows in schematic form a modified version of the tape binding apparatus 2′. The tape binding apparatus 2′ has a number of features in common with the tape binding apparatus shown in FIGS. 1 to 12. Accordingly, like numerals reflect like parts. However, where the parts have been adapted to conform to the new embodiment, a prime symbol (′) will be used to indicate a modification to that part.
The mechanical aspects of the tape binding apparatus 2′ may be substantially similar to that of the tape binding apparatus 2 in that it includes a turntable 4 with a toothed wheel 62. The sensor 60 determines the passing of the toothed wheel and pulses are counted by controller 108′. A mast 8 with a moveable carriage 12 driven via a drive chain 42 is provided. The carriage 12 carries a roll of tape 17.
Additionally, the carriage includes a detector 900 in the form of a photoeye which projects a beam of infrared light in a substantially horizontal direction towards the load. The photoeye 900 is able to detect light which is reflected back from the load and can thus accordingly detect the presence of the load. The photoeye 900 is attached to the carriage 12 and thus moves with the carriage 12. The photoeye 900 will thus detect when the carriage 12 has moved beyond the top of the load. Through the use of photoeye, the top of the load will be detected automatically and accordingly, it will not be necessary for the operator to measure the height of the load and key this in through the keypad.
The carriage motor 44′ has associated therewith a toothed wheel 66. The sensor 64 is mounted adjacent the toothed wheel in order to sensor the number of teeth passing on the toothed wheel 66. pulses are fed to the controller 108′ where they are counted to determine the displacement of the carriage 12 along the mast 8. A sensor 902 is also mounted adjacent the toothed wheel 66 in order to determine the direction of rotation of the toothed wheel 66. Accordingly, the sensor 902 is able to verify whether the carriage is travelling up or down.
A lower limit sensor 906 is provided to detect when the carriage is at the lower extremity of the mast. The carriage cannot drive below this lower extremity. The bottom limit sensor is used to zero the count from the sensor 64 which provides an indication of the carriage position on the mast.
A mast top limit sensor 904 is provided to indicate that the carriage is at the upper extremity of the mast 8. The carriage cannot drive above the upper extremity.
The keypad allows the operator to key in various load parameters as well as selected pattern parameters. In this embodiment, these include the minimum tape height H_min, top drop T_d, pallet dimensions of length L_pand breadth. Additionally, the operator may input an incremental X number. This is the variation to the default X number which would be automatically determined by the machine given the pattern selection and load parameters. For example, the operator may key in plus 1 which would result in an additional X applied to the load. Plus 2 will result in two additional Xs. Minus 1 will result in a lesser number of Xs etc. The operator may alternatively select the default setting.
The operator may also key in the maximum speed of the turntable. The turntable will not rotate above this speed. The turntable speed is automatically calculated (as will be explained). Thus, if the calculated value exceeds the maximum speed entered by the operator, the turntable will run at maximum speed.
The above parameters which are entered by the operator tend to be based on the type of product being bound not the actual load being bound. For example, in order to bind a load of bottles set on trays in layers, the minimum tape height and pallet dimensions may be determined by the type of pallet that the bottles are typically loaded onto. Top drop will be influenced by the shape of the bottles and likewise X number. The maximum speed will reflect the maximum speed that the turntable can be rotated without the bottles falling off the load. Thus, once these parameters are set by the user, they need not be changed from load to load.
The operator may also key in other parameters e.g. selection of looping or banding etc. Importantly, the actual load height does not need to be keyed in as this is automatically determined by the photoeye 900.
Thus it can be seen from FIG. 23 that the controller 108′ receives inputs from the turntable sensor 60, the top limit sensor 904 and the bottom limit sensor 906, the photoeye 900, the carriage position sensors 64 and 902 and the keypad 67. The controller 108′ may conduct calculations based on the inputs in order to bind the load with tape. Based on these calculations, the controller 108′ will generate outputs to the turntable speed drive 106 to drive the turntable motor 32 and to the variable speed drive 104′ of the carriage to drive the carriage motor 44′. The infinitely variable speed drive 106 receives an analog signal from the controller 108′ to drive the variable speed motor 32.
The variable speed drive 104′ for the carriage drives the carriage motor 44′ at either of two speeds i.e. either fast or slow. Furthermore, the carriage motor 44′ may be driven in either direction resulting in the carriage travelling up or down. There are three outputs from the controller 108′ to the variable speed drive 104′. These include up, down and fast. If there is a fast output from the controller then the carriage will be driven at the fast speed. Otherwise, the carriage will drive at the slow speed. These fast and slow speeds may be inherent in the variable speed drive 104′.
The diagrams of FIGS. 24 and 25 show the sequence of applying tape to a load using the apparatus of FIG. 23. In step 601, the operator attaches the tape to the load and presses the start key on the keypad. The carriage 12 then drives to the lower extremity of the mast where it stops. The mast proximity counter associated with sensor 64 is then zeroed. The carriage then drives up to the minimum tape height as input by the operator and stops.
In step 602, the turntable begins to rotate. After a ¼ of a turntable revolution, as shown in step 603 the carriage begins to ascend at a slow speed. However, as the carriage begins the binding sequence at the bottom of the mast 6, the photoeye 900 has not detected the height of the load and thus the appropriate calculations to determine pitch cannot be done by the controller 108′. Accordingly, the tape is applied at a default pitch. This default pitch will depend upon the incremental X number. If the incremental X number is the default factory setting, then the default pitch P _dwill be 330 millimeters. The following sets out the default pitches P_d, based on the operators selected incremental X number:

X number plus 2, tape pitch: 250 millimeters
X number plus 1, tape pitch: 280 millimeters
X number F, tape pitch: 330 millimeters
X number minus 1, tape pitch: 400 millimeters
X number minus 2, tape pitch: 500 millimeters

The above default pitches are merely examples and different values could be provided where the turntable and/or carriage speeds are altered.
The carriage will travel upward to apply the tape at the default pitch until the photoeye 900 detects the top of the load. The photoeye 900 is a sufficient distance above the tape dispenser apparatus in order that the photoeye will detect the top of the load before the tape reaches the top drop. When the photoeye detects the top of the load in step 605, the controller 108′ reads the mast pulse count, thus measuring the height of the load. By deducting the top drop and the minimum tape height, the controller can determine the array height. Once the array height is known, the corrected pitch H_bcan be determined. The corrected pitch H_bis determined by dividing the array height by the default pitch. The resultant number is then rounded to the closest whole number to obtain the X number. The corrected pitch H_bis then derived by dividing the array height by the X number. This can be represented as
A/P_d=Z
Round Z to nearest whole number (X)
H_b=A/X
Thus, as shown in steps 607, 608 and 609, the tape will be applied to each side of the load at a corrected pitch H_b.
However, it will be appreciated that in the step 603, 604 and 605, the application of tape at the default pitch will hardly ever coincide with the top drop T_dat the top of the upward helix. Accordingly, some adjustment will be required for the tape to reach the top drop position. When the photoeye detects the top of the load, as described above, the controller 108′ will be able to determine the array height, and from this the required number of tape crossings at the default pitch for the tape to reach this tape height. Thus the controller can determine how far the load should rotate until the required side of the load is presented for tape to be applied. At the time of detecting the top of the load, the controller 108′ reads the turntable pulse count which determines the orientation of the turntable 4 from information supplied by sensor 60. The pulse count will enable the controller to determine the actual orientation of the turntable. Thus, the controller will control the turntable to continue to rotate until the required face of the load is presented which coincides with the top of the tape ascent.
If the turntable is already presenting this face, binding as per the corrected pitch will start immediately. If the required face is yet to be presented the turntable will continue to rotate. The example shown in sequence step 606 shows this situation where a small increment in tape height is required in order to reach top drop. This tape is applied at an adjusted pitch P_a. If however the required face is already being presented when the top of the load is detected, then an adjustment may be required in step 605 if the remaining distance to reach top drop is less than the default pitch. Accordingly, in step 605 the pitch would be less than the default pitch shown. In this eventuality, in step 606, the tape would be applied level.
From step 607 onwards, the apparatus continues to bind the load according to the corrected pitch resulting in a corrected pattern applied to the load. It will be appreciated from FIGS. 24 and 25 that the tape goes up and down four times in order to bind the load. One of these ascents will be according to a default pattern and a default pitch, whereas the remaining ascents and all the descents will be according to the corrected pattern at the corrected pitch. Thus, ⅛^thof the binding pattern will be at the default pitch whereas ⅞^thof the binding patterning will be at the corrected pitch.
From step 607 onwards, the carriage travels at the fast speed. It is to be understood that the carriage only has two speed options being fast and slow and both the fast speed and the slow speed are substantially constant apart from the necessary deceleration and acceleration required when transitioning from up to down.
Given that the carriage travels at a constant speed, it is thus necessary for the turntable to travel at variable speeds in order that the pattern may be applied to the load in the desired manner. At the default pitch, the required positions for the tape dispenser at each quarter revolution can be determined. Likewise, once the corrected pitch has been calculated, the required positions for the carriage at each quarter revolution of the turntable will be known. The controller 108′ thus calculates the required speed for the turntable so that it travels exactly ¼ revolution in the time taken for the carriage to travel from one destination to the next. The turntable speed calculation means that the carriage will not actually stop at the required position. Rather, a constant speed will be maintained for each ascent and descent (subject to acceleration and deceleration at the extremes). As the distance between carriage destinations will vary, depending upon whether it applies sequential inclined runs of tape or horizontal bands of tape, the turntable's speed will continually adjust itself accordingly. For example, when horizontal runs of tape are applied in banding or at the bottom of the load, the distance to the next carriage destination will thus be small (or zero in the case of two sequential horizontal runs of tape). The calculated turntable speed will thus be high. In such a case, the turntable will rotate at the maximum speed which was input by the operator. This method of speed control results in the absolute minimum cycle time because it enables the carriage to run at the fastest possible safe speed i.e. a speed which is not dangerous and also allows appropriate stopping at the upper and lower limits as required. Thus, the turntable adjusts to suit this maximum possible speed. This is a great saving in the binding time for a load over existing methods because in existing methods the speed of the carriage (which needs to travel up and down at least four times) is the limiting factor.
In step 637 shown in FIG. 25, the turntable slows to predetermined creep speed and then stops at the same rotational position from which it started.
FIG. 30 illustrates a variation which may be applied to any of the binding sequences illustrated in FIGS. 21, 22, 24, 25, 28 and 29. Instead of the operator needing to bend over to apply the tape to the base of the load, there is a programmed “home position” 920 for the carriage which is at an appropriate height for the operator to grab the end of the tape and apply it to the load at that height. This saves the operator from having to bend down.
It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.

Claims

1. An apparatus for binding a three-dimensional load with tape, the apparatus comprising:

a turntable for supporting and rotating the three-dimensional load;

a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load;

a logistical controller arranged to control rotation of the load and movement of the tape dispenser; and

a detector to detect the top of the load, the detector being moveable with the tape dispenser, wherein the controller is arranged to operate the apparatus to dispense the tape according to a predetermined default pattern until the detector determines the top of the load, whereafter, the controller is responsive to a signal from the detector corresponding to the detected top of load to operate the apparatus according to a corrected pattern based upon the detected top of load.

2. The apparatus as defined in claim 1 wherein the tape dispenser is provided on a moveable carriage driven up and down a mast, and the detector is mounted on the carriage.

3. The apparatus as defined in claim 2 wherein the detector is spaced above the tape dispenser to provide advance warning to the controller in an upward path of the tape dispenser that the tape is approaching the top of the load.

4. The apparatus as defined in claim 1 wherein the corrected pattern applied to the load is a helical pattern comprising a plurality of upward and downward helixes which are spaced from each other with at least some of the upward helixes crossing at least some of the downward helixes, the upward and downward helixes extending between upper and lower limits and wherein the default pattern comprises an upward helix and the controller operates the apparatus to dispense the tape in the upward helix of the default pattern according to a default pitch.

5. The apparatus as defined in claim 4 wherein the tape is applied at a default pitch until the detector detects the top of the load, whereafter the controller calculates a corrected pitch and operates the apparatus to apply the remaining upward and downward helixes at the corrected pitch.

6. The apparatus as defined in claim 5 wherein the corrected pitch is calculated so that the tape will be applied to a whole number of sides of the load as it traverses between the upper and lower limit and vice versa.

7. The apparatus as defined in claim 1 wherein the controller controls the apparatus to commence at an intermediate height of the load.

8. The apparatus as defined in claim 4 wherein the controller is arranged to receive a number of user inputs through the use of a keypad or other data entry means including values corresponding to the upper and lower limits of the pattern array, the pattern array being the vertical extent of the applied default and corrected helical patterns.

9. The apparatus as defined in claim 8 wherein the controller is arranged to calculate the array height from an input from the detector and the values corresponding to the upper and lower limits of the pattern array and wherein the controller determines the corrected pattern based on the array height.

10. The apparatus as defined in claim 4 wherein the controller determines an adjustment which is required in the default pattern so that the tape reaches the upper limit coinciding with the end of an inclined pass of tape across a side of the load.

11. A method of binding a three-dimensional load with tape, the method comprising:

a) binding the load with tape dispensed from a movable tape dispenser according to a default pattern;

b) detecting the top of the load by a detector moveable with the tape dispenser during step a); and

c) binding the load with a corrected pattern based on the detected top of load.

12. An apparatus for binding a three dimensional load with tape, the apparatus comprising:

a turntable to rotate the load;

a carriage to carry a tape dispenser for movement along an upward path and a downward path adjacent the load;

a controller to control the movement of the turntable and the carriage to bind the load according to a desired pattern, wherein the controller comprises a computer program which calculates the required turntable speed for a substantially constant predetermined speed of the carriage over a substantial portion of the upward path or a substantial portion of the downward path such that the relative position of the turntable and the carriage is such that the load is bound according to the desired pattern.

13. The apparatus as defined in claim 12 wherein the carriage speed is constant over an intermediate portion of both of the upward and the downward paths to allow for acceleration and deceleration at the extremes of the paths.

14. The apparatus as defined in claim 13 wherein the apparatus is operable to determine predefined parameters of the load during the binding operation and the carriage has two possible constant speeds being a fast speed and a slow speed and wherein the controller is arranged to operate the apparatus to apply tape at the slow speed to apply a default pattern which is pre-programmed into the controller and the controller is arranged to operate the apparatus to apply tape at the fast speed according to a pattern which is determined by the controller once the predefined parameters of the load are determined.

15. The apparatus as defined in claim 12 wherein the apparatus is adapted to bind a three dimensional load which is square or rectangular and the desired pattern for the tape is broken down into segments of quarter turns of the turntable by the controller to determine, for each quarter turn: the required position of the carriage to apply tape according to the desired pattern; when the carriage will arrive at the required position; and the speed of the turntable required to rotate the load through said quarter turn.

16. An apparatus for binding a load with tape, the apparatus comprising:

a turntable for supporting and rotating the three-dimensional load;

a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load; and

a logistical controller arranged to control rotation of the load and movement of the tape dispenser; wherein the controller is arranged to operate the apparatus to dispense the tape according to a desired pattern comprising a plurality of helical paths, each path including at least one upward helix, a loop over the top of the load and a downward helix giving rise to a pattern whereby the upward and downward helixes are transversely spaced from each other and each upward helix crosses with at least one downward helix.

17. The apparatus as defined in claim 16 wherein the apparatus includes a data entry means for the operator to select the desired pattern from a variety of pattern options.

18. The apparatus as defined in claim 17 wherein the data entry means is also adapted to receive operator entry of one or more parameters of the looping.

19. An apparatus for binding a three-dimensional load with tape, the apparatus comprising a turntable for supporting and rotating the three-dimensional load; a tape dispenser for dispensing tape, the dispenser being moveable relative to the turntable and the load; and a logistical controller arranged to control rotation of the load and movement of the tape dispenser, wherein the logistical controller controls the operation of the apparatus to bind the load with tape according to a desired pattern; and means for inputting into the logistical controller, one or more values corresponding to one or more selected heights, wherein the logistical controller controls the operation of the apparatus to apply substantially horizontal over-bands over the desired pattern at the one or more selected heights.

20. The apparatus as defined in claim 19 wherein the desired pattern applied to the load is a helical pattern comprising a plurality of upward and downward helixes which are spaced from each other with at least some of the upward helixes crossing at least some of the downward helixes

21. An apparatus for binding a three-dimensional load with tape, the apparatus comprising:

a turntable for supporting and rotating the three-dimensional load;

a logistical controller arranged to control rotation of the load and movement of the tape dispenser to dispense tape onto the load in a desired pattern, wherein the controller is programmed to position the tape dispenser at a home position which is at a convenient height for the user to position tape on the load and wherein the controller is arranged to control movement of the tape dispenser to a start position to commence application of tape to the load in the desired pattern.