WO2003020591A1

WO2003020591A1 - Method and system of wrapping a load

Info

Publication number: WO2003020591A1
Application number: PCT/AU2002/001208
Authority: WO
Inventors: Bruce Cox; David Wakefield; Lindsay Wakefield
Original assignee: Safetech Pty Ltd
Priority date: 2001-09-03
Filing date: 2002-09-03
Publication date: 2003-03-13
Also published as: EP1463665A1; AUPR743201A0

Abstract

A system for wrapping a load with a tape in a predefined manner, the system including: a turntable (14) for supporting the load, turntable drive means (37) for causing rotational movement of the turntable, a mast assembly (8), a carriage assembly (12) mounted to the mast assembly, carriage assembly drive means (44) for driving the carriage assembly along the mast assembly, tape dispensing means (13) attached to the carriage assembly, and a control system (100) for controlling operation of the carriage assembly drive means and the turntable drive means, the control system including processing means (108) and associated memory means (112) for storing program instructions to cause the control system to displace the carriage assembly along the mast so that, as turntable is rotated, the tape is applied to secure the load in one or more predefined patterns.

Description

METHOD AND SYSTEM OF WRAPPING A LOAD

The present invention relates to a method and system for wrapping a load, and more particularly relates to a method and system of wrapping a load with tape in a predefined pattern or a combination of predefined patterns. The invention also relates to a computer program for facilitating the wrapping of the load in a predefined pattern or a combination of predefined patterns.

In securing a load, such as a stack of containers or boxes, which is supported on a pallet, stretch film is used which is paid out from a load wrapping machine that has a turntable on which the load to be wrapped rotates. Thus as the load rotates the stretch film secures the box of containers or the like so that it can then be transported to another area in a building or transported by freight.

In situations where each container within the load or various packaging comprising the load consists of goods that need to be cooled, such as dairy products and in particular yoghurt, the stretch film cannot be applied immediately. The containers of dairy produce must first of all be allowed to cool which necessitates that the containers of produce must be stored elsewhere and then wrapped with stretch film. This creates in effect a double handling or double movement of the produce whereby first of all they must be placed on a pallet and moved by fork lift to another area, allowed to cool and then brought back to' the stretch wrapping machine to be wrapped in stretch film and thereafter transported by freight.

One of the problems with having to allow the load cool first is that vehicles or auto guided vehicles in moving the load lose a certain percentage of the produce when, for example, the pallet is snagged or the load has otherwise moved. This is due to the fact that the load cannot be contained or secured before cooling.

However, in order to overcome the possible loss of containers or cartons in moving the load or even before the produce has had time to cool, film is often temporarily used to secure the load even while the produce might still have a time to cool down. In these situations the temporary film has to be cut off and removed, which adds an extra step in the process, and also the produce has no breathability in that no air flow is able to go through the load or the stack of containers. Thus there is limited ventilation which slows the cooling process even more and condensation can occur within the packaging which if the goods are cans can often rust and therefore contaminate the produce. Thus temporary wrapping of stretch film around a load or wrapping a load of stretch film prior to the contents coding can impede the cooling and produce condensation.

Furthermore, there is a lot of waste material used in providing temporary wrapping and even final wrapping using stretch film.

Other alternatives have been proposed whereby stretch film having apertures or holes therein is used to wrap a load. However, once the film covers the load with two or three layers the holes or apertures are covered and therefore disables ventilation and leads to the above-mentioned problems. Another arrangement involves netting, which may be stretched or unstretched, used to wrap a load. However, use of netting is an expensive alternative and has the same waste volume as stretch film does. Another arrangement involves splitting the stretch film and roping the load which requires a lot of coverage for sufficient integrity of the load and thereby adds to the cost and increases wastage.

The present invention uses tape to secure a load. Tape is stronger and thicker than stretch film and has greater load containment strength than stretch film. Tape also has better load attachment qualities than stretch film. The present invention, by using tape, allows wrapped loads to have the necessary breathability for ventilation which eliminates condensation. It also reduces the double handling of the load as mentioned previously and substantially reduces the volume or amount of waste compared to stretch film. A minimum amount of tape used can be determined to give the same integrity of the load as would stretch film. By assessing the particular load to be wrapped, a variety of wrapping patterns can be applied to secure the load and achieve an efficient containment of the load with a minimum of tape usage. This is particularly advantageous where parts of a wrapped load need to be separated and left in a particular location.

It would be desirable to provide a method and system for wrapping a load with tape in a predefined pattern that ameliorates or overcomes one or more disadvantages of existing tape wrapping methods and systems.

With this in mind, one aspect of the invention provides a system for wrapping a load with a tape in a predefined manner, the system including: a turntable for supporting the load; turntable drive means for causing rotational movement of the turntable; a mast assembly; a carriage assembly mounted to the mast assembly; carriage assembly drive means for driving the carriage assembly along the mast assembly; tape dispensing means attached to the carriage assembly; a control system for controlling operation of the carriage assembly drive means and the turntable drive means; and the control system including processing means and associated memory means for storing program instructions to cause the control system to displace the carriage assembly along the mast so that, as turntable is rotated, the tape is applied to secure the load in one or more predefined patterns.

In one embodiment, the program instructions cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to at least a portion of the load in a series of spirals where the tape crosses itself at multiple positions on one or more faces of the load.

The tape crossings may be calculated by the processing means from crossing number characterising the number of desired crossing positions on the one or more load faces. The tape crossing positions may be calculated by the processing means from crossing position data characterising the position of each desired crossing position on the one or more load faces.

The load portion may include a plurality of layers, the tape crossing itself once at each layer.

The tape may also be applied about the load portion in a first band at an uppermost tape crossing point.

The tape may also be applied about the load portion in a second band at a lowermost position. The load may include one or more articles supported by a pallet, and the second band may be applied about the pallet.

The band application positions may be calculated by the processing means from band position data.

The tape may be applied multiple times about an uppermost portion of the load. The multiple applications of the tape about an uppermost portion of the load may be offset from each other.

The tape may be applied multiple times about a lowermost portion of the load. The multiple applications of the tape about the lowermost portion of the load may be offset from each other.

The program instructions may cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to at least a portion of the load in a plurality of bands about the load. The tape may fleet between adjacent bands.

The band application positions may be calculated by processing means from band position data. The program instructions may cause the control system to displace the character assembly and rotate the turntable so as to apply the tape to at least an uppermost position of the load from a first face across the top of the load to a second face. The program instructions may cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to at least a portion of the load in accordance with load dimension data.

The data described above may be input into the processing means from a data entry device.

Another aspect of the invention includes a computer program for use in a system for wrapping a load with the tape in a predefined manner: a turntable for supporting the load; turntable drive means for causing rotational movement of the turntable; a mast assembly; a carriage assembly mounted to the mast assembly; carriage assembly drive means for driving the carriage assembly along the mast assembly; tape dispensing means attached to the carriage assembly; a control system for controlling operation of the carriage assembly drive means and the turntable drive means; and the control system including processing means and associated memory means for storing program instructions to cause the control system to displace the carriage assembly along the mast so that, as turntable is rotated, the tape is applied to secure the load in one or more predefined patterns.

The program instructions may cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to at least a portion of the load in a series of spirals where the tape crosses itself at multiple positions on one or more faces of the load. The program instructions may cause the processing means to calculate tape crossing positions from crossing number data characterising the number of desired crossing positions on the one or more load faces. The program instructions may cause the processing means to calculate the tape crossing positions from crossing position data characterising the position of each desired crossing position on the one or more load faces.

The program instructions may cause the processing means to calculate band application positions from band position and data.

The program instructions may cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to the portion of the load in a plurality of bands about the load.

The program instructions may cause the processing means to calculate band application positions from band position data.

The program instructions may cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to at least an uppermost portion of the load from the first face across of the top of the load to a second face. The program instructions may cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tapes to at least a portion of the load in accordance with load dimension data.

The following description refers in more detail to the various features of the load wrapping method, and system and computer program of the present invention.

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:

Figure 1 is a plan view of a tape wrapping apparatus according to a first embodiment of the invention; Figure 2 is a side view of the tape wrapping apparatus shown in Figure 1; Figure 3 is a detailed section of plan view showing various components of the turntable and a drive means for driving the turntable of the tape wrapping apparatus of Figure 1;

Figure 4 is a side sectional view of the turntable shown in Figure 3; Figure 5 is a side view of a mast assembly together with a carriage assembly and tape dispenser of the tape wrapping apparatus shown in Figure 1;

Figure 6 is an end view of the tape wrapping apparatus shown in Figure 5;

Figure 7 is a plan view of the tape wrapping apparatus shown in Figure 5; Figures 8 to 10 are enlarged views of Figures 5 to 7 respectively;

Figure 11 is a schematic diagram illustrating various functional components of a control system for controlling the operation of the tape wrapping system shown in Figures 1 to 10;

Figure 12 is a side view of the mast assembly and a load supporters on the turntable showing attachment of the tape material to the load;

Figures 13 and 14 are a flow chart illustrating steps performed by the control system shown in Figure 11 to control operation of the tape wrapping system shown in Figures 1 to 10;

Figures 15 to 21 show exemplary loads when wrapped with various tape wrapping patterns by the tape wrapping system shown in Figures 1 to 10;

Figures 22 and 23 provide various views of each of the faces of a load as it is wrapped by tape from the tape wrapping system shown in Figures 1 to 10;

Figure 24 is a diagram of a load when wrapped with tape in multiple patterns; and Figure 25 is a schematic diagram of the four faces of the load shown in

Figure 24 showing tape being applied to the faces of the load as the tape is dispensed from the tape wrapping apparatus shown in Figures 1 to 10.

Referring to Figures 1 to 4, there is shown generally an apparatus 2 for palletising and wrapping a load 18. The apparatus 2 comprises a turntable 4 and wrapping apparatus 6. The wrapping apparatus 6 includes 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 wrapped 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 (3M) Company, or tape as disclosed in the specification of US Patent No. 5,496,599 in the name of 3M. Details of the pre-tensioning assembly 20 are disclosed in the specification of PCT Application No. WO 02/30751 in the name of the present applicant.

The turntable 4 is constructed substantially in accordance with the specification of Australian Patent No. 615,778 in the name of the present applicant. 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 circular sprocket 26 which has teeth adapted to engage an endless drive chain 28 which passes around the sprocket 26 and a drive sprocket 30. The drive sprocket 30 is driven an electric motor 32, or other turntable drive means. Referring to Figures 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 wrapped around the palate load 18 in a helical or circular manner. Particular patterns of the helical/circular wrapping 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 Figure 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 wrapping process of the palletised load 18.

As can be seen in Figure 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) 104 adapted to drive the motor 44 controlling carriage assembly movement, and VFD 106 driving the motor 32 controlling turntable rotation. The VFD 104 and 106 are supplied with 240 volts AC from the mains supply 102.

A micro processor 108 is supplied with 12 volts DC from the mains supply 102 through a transformer 110. The micro processor 108 is housed in the control panel structure 67 attached to the mast assembly 8. Control signals are sent from the micro processor 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 micro processor 108 are dependent upon the output signals of the sensors 60 and 64, which are supplied to the micro processor 108. A keypad 114 is provided to enable the entry of data by and operator of the load wrapping apparatus 2, 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 Figure 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 micro processor 108 from the sensor 60 to correspond to a 90° rotation of the turntable 4 is pre-stored in the micro processor 108 so that when an internal counter reaches that number of pulses, the micro processor 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 micro processor 108 is able to determine the distance travelled along the mast.

In Figure 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 four containers 21.

The length of the load 18 is a fixed distance L _ι 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 Figure 12, it is desired for the tape 80 to run from a point halfway up the rear facing of the container at the lower layer of the load 18 to a point halfway up the container to the front of the second lower most layer. The micro processor 108 is programmed with data corresponding to the distances L and L_c, and in some embodiments of the invention the vertical distance H across which the tape 80 travels across a face of the load 18 during application of the tape 80. From the data corresponding to the distances L_bj L_c and H , the micro processor 108 is able to determine the distance H_c through which the tape dispensing apparatus must travel in order that the tape be applied to the load 18 to form a desired predetermined pattern. The micro processor 108 applies tape 80 to the load 18 in one or more predefined patterns by causing the motor 44 to drive the carriage assembly up or down the mast 8 so that the tape dispensing means 20 dispenses tape from a desired height, and by causing the motor 32 to drive the turntable 4 so that the face of the load 18 to which the tape is to be applied is brought into engagement with the tape after the carriage assembly 12 has reached its desired position. In the exemplary arrangement shown in Figure 12, the load 18 and pallet 23 have four faces, 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.

Figures 13 and 14 illustrate a series of steps that the computer program stored in the PROM 112 causes the micro processor 108 to undertake in order to apply a predetermined pattern to the load 18. 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. At step 204, the program is then activated by the wrapping apparatus operator. At step 206, the micro processor 108 features 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 micro processor 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 occuned, the micro processor fetches instructions for the second cycle of the program. In this step, the micro processor 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 wrapping 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 micro processor determines whether more than X cycles have occurred, where X corresponds to the number of faces to which the tape is to be applied in a generally upward direction. Accordingly, at step 112 the micro processor 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 conespond 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 Y such cycles, and accordingly at step 226, a determination is made as to whether these Y 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 predefined patterns may be applied to the load 18. Different predefined patterns may be attired to the entirety of the load 18, alternatively different predefined patterns may be applied to separate portions of the load 18. One predefined pattern, referred to by the applicant as the "multi-X" pattern, is illustrated in Figure 15. In this predefined pattern, tape is applied to the load 18 in a series of counter-handed spirals positioned so that the spirals cross at a predetermined location. In this embodiment, the spirals cross at the predetermined location but in a preferred embodiment at the comers of the load at the mid height of layer. In Figure 15, the load 300 includes 4 layers 301 to 304 each of the comers 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 position of the tape crossing points at the corners of the load 300 can be manually selected to occur at any position along the load comers "CUSTOM-X", or basic parameters of the load 300 can be entered by the operator via the keypad 114 - such as the tape height, number of layers in the load and pallet dimensions - and the micro processor 108 of the control system 100 automatically performs calculations to correctly apply the tape to the load 300.

An alternate pattern is shown in Figure 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 indicated, respectively applied around the uppermost layer and the second lowermost layer of the load. The micro processor 108 causes the carriage assembly 12 to be driven between the two positions required to apply the two banks 306 and 307, so that a spiral of tape 308 is applied between the bands as the tape fleets up or down between banding levels.

Following initialisation, an operator is able to use the keypad 114 to select one of ten menus displayed by the display 116. These ten displays are as follows: 1. "AUTO-X" mode.

Either is presented with a display of the following information:

AUTO-X SET 1-8

TOTAL X NO 1-8 TOP-X 38-2730 MM BOT-X: 38MM-2730MM Eight multi-X patterns can be saved in the "AUTO-X" mode using the "set" function.

These are recalled by selecting any one of the saved patterns numbered 1 to 8. Upon initialisation, the display indicates "set 1 ". Values then keyed in are automatically saved as set 1. The operator may use the keyboard to scroll to a next set before keying in a new predetermined pattern to be applied to a load. This process can be repeated to save up to eight different patterns.

An operator can select the total number of "X layers", namely the total number of "Xs" formed at the comers of the load when the tape 80 crosses over itself. Unlike the wrapped load illustrated in Figure 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. The "TOP-X" value can be entered by the operator. This position is the height on the load where an uppermost layer of tape will be applied in a horizontal band.

The value "BOT-X" is entered by the operator to indicate the position on the load where the lowest layer of tape is to be applied in a horizontal band. In operation, the display 116 will show the following information to the operator:

AUTO-X #RPM

STEPS #OF ## MPPROX: ###TLIM:0 TPROX: #### BLIM:0

##RPM is the turntable rotation speed automatically selected by the micro processor 108. Depending upon the number of Xs selected either automatically or by the operator, the micro processor 108 will cause the VFD 106 to increase or decrease the speed of turntable rotation caused by the motor 32.

2. CUSTOM-X MODE

When this mode is selected by an operator, the following information is displayed:

CUSTOM-X SET 1-7

TOTAL X NO 1-8 BOT X ATTACH/1 -7/TOP STRAP HEIGHT: 38MM-2730MM

This mode enables an operator to select each parameter of a multi-X pattern, including band spacing and placement. Taping selection begins with the height at which the tape is initially attached to the load, and then allows up to seven individual height of X points to be programmed by the operator. In this way, complete flexibility is provided to the operator to construct any customised pattern in order to contain non homogeneous loads.

3. SET 8 CUSTOM-X MODE

In this mode, the following information is displayed to the operator

CUSTOM-X SET 8

TOTAL X NO 1-7 BOT X ATTACH/1 -7/TOP STRAP

HEIGHT: 38MM-2730MM

In this mode, a single band of tape, or a top strap, is applied to the load above the main pallet load to contain items placed on the load as a partial layer. For example, the last few cartons of a production run where there are insufficient quantities of cartons to make up a full layer. Typically, the top strap is constructed at the start of a multi-X sequence to lock in the side straps and retain load integrity if the partial layer is removed. All heights may be manually selected by the operator, including the top strap height.

4. BANDING MODE In this mode, the operator is displayed with the following information:

BANDING SET 1-8

TOTAL BANDS 1-6

BAND NO START/1 -6/FINISH B. HEIGHT: MM

Up to eight "banding" patterns can be stored in the micro processor. These patterns may be saved and recalled in the same way as the "AUTO-X" or "CUSTOM-X" patterns previously described. The field "total bands" is used to select the total number of horizontal bands required to be applied to a load. "Start" indicates the height of the point of attachment of the tape to the load. The band number (1-6) is the height of each band, whereas "finish" is the selected tape finishing height.

5. OPTIONS SCREEN

In the options mode, the following information is presented to the operator:

OPTIONS

FULL TOP BAND Y/N HEAVY DUTY TOP: Y/N BOT: Y/N

In the options mode, an operator is able to select or deselect a full top band option, a heavy duty top or a heavy duty bottom. A full top band selection causes a top strap of tape to be applied around the entirety of the load 18 at the top of an AUTO-X pattern early in the tape wrapping process in order to lock pallet caps or unstable loads in place. Selecting a heavy duty top will cause the upper portion of the load to have applied thereto an additional or double taping in order to increase load retention strength. Rather than applying the tape directly on top of the existing tape, the heavy duty pattern causes the tape to be applied at an offset position in order to minimise any tendency for the tape to crush the comers of the containers. Similarly, selection of heavy duty bottom will cause the bottom of the load to be double taped. 6. SELECT PALLET SCREEN

In this mode of operation, the operator is presented with the following information:

PALLET CHEP: Y/N

LENGTH: 116O/#### WIDTH: 116O/####

This screen enables an operator to enter dimensions of a pallet upon which the load 18 is to be stacked. It will be noted that the load dimensions and the pallet dimensions are typically the same, however in those instances where the load to be contained is smaller than the pallet dimensions the operator will use the select pallet screen to input the dimensions of the load.

7. MANUAL SCREEN

In this mode the operator is presented with the following information:

MANUAL

ROTATE SLOW FAST

UP SLOW FAST

DOWN SLOW FAST

This mode enables the manual positioning of the carriage assembly 12 and the turntable 4, and is typically used for quick manual banding of the load 18.

In order to contain the load 300 with the AUTO-X pattern shown in Figure 17, the operator would use the keypad 114 to enter the dimensions of the pallet, and hence the load, via the select pallet screen. The operator would then enter appropriate selections on the options screen to determine whether a single band was required around the top of the load, and whether an extra "X" was required around the top and/or base of the load. On the "AUTO-X" screen, the operator would select the total number of Xs required in the pattern (in this example 4), the height of the top layer of tape (TOP-X) and the height of bottom layer of tape (BOT-X). The operator would then load and thread the tape 17 in the tape dispensing means 20 and place the pallet load on the turntable 4. The turntable would then be rotated until the shortest side of the pallet was closest to the mast 8. The tape is then manually pulled away from the tape dispensing means and the operator applies an adhesive end of the tape to the load. The operator then causes the micro processor 108 to start the tape wrapping program by sequentially fetching instructions for the application of a predetermined pattern to the load, in this case "AUTO-X" pattern and applies the tape in that pattern according to the operator entered load variables. The rotational speed of the turntable 4 is varied automatically by the micro processor 108 and variable speed drive 106 in order to allow the carriage assembly 12 to reach an intended destination within one quarter turn of the turntable 4. When each set of instructions is executed and the tape wrapping fully applied to the load, the turntable is caused to revert to creep speed and continues to rotate until it returns to its starting position. The tape is then disengaged from the tape tensioning device 20 and the loose end of the tape applied to the load.

In order to apply the "CUSTOM-X" pattern shown in Figure 18 to the load 300, the operator enters the pallet, and/or load, dimensions via the pallet screen. In the CUSTOM-X screen, the operator selects the total number of multi-X layers of tape to be applied to the load, the height of the bottom layer of tape to be applied to the load (BOT-X) and then the individual height of each X position. In this example, four X heights are selected. Tape is then applied and wrapped as previously described in relation to Figure 17. In Figure 19, the load 300 is shown, to which a partial load 301 has been added. In order to contain the entire load 300, 301, the operator may select a CUSTOM-X. In the case where the operator selects a CUSTOM-X taping with a top strap entry, following entry of the pallet dimensions on the pallet screen, and entry of the heights of the individual X points at which tape crossings are to occur at the comers of the load, the user is required to enter the top strap height. The taping sequence performed by the tape wrapping apparatus is then carried out in the manner described with respect to the CUSTOM-X tape wrapping of Figure 18.

Should the operator wish to apply the banding pattern shown in Figure 20 to the load 300, the operator selects the banding screen, 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 Figure 21, in this pattern, tape is applied over the top comers 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 provide multi-X 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.

Figures 22 and 23 show the four faces A to D of a load 500 consisting of two layers 501 and 502 stacked on a pallet 503. The exemplary load positions referenced 401 to 432 in these Figures demonstrate the manner in which an AUTO-X pattern is applied to the load 500 by the tape wrapping apparatus 2. Initially, the operator from the AUTO-X screen selects 3 multi-X layers to be applied to the load 500 and the height of the top and bottom layers of tape (TOP-X and BOT-X) respectively reference 504 and 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 BOT-X height 505. Since three multi-X layers have been chosen, the height at which the spirals of tape will cross at the edges of the load 500 will be mid way between the TOP-X and BOT-X 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 is applied between the BOT-X 505 and the intermediate height 506. In position 403, the load 500 is again rotated and the carriage is simply driven to a height in order that tape can be applied on face C from the intermediary X point height 506 to the TOP-X height 504. At position 404, the carriage assembly is driven to the TOP-X height 504 in order to dispense tape horizontally and apply a portion of the top band of the multi-X pattern at the top 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-X 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 BOT-X 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 BOT-X height 505. Positions 409 to 432 illustrate the manner in which the tape is applied to complete the multi-X pattern to the load 500. It will be appreciated that having entered data indicative of the pallet and/or load and the characteristics of the pattern to be applied to the load, together with known physical dimensions of the carriage assembly, tape dispenser and displacement between the mast 8 and the centre of the turntable, the micro processor 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. Figure 24 illustrates an example of a load 602 essentially divided into three portions, a lower portion 606 a middle portion and an upper portion 610. The lower portion 606 contains two layers of containers 612 and 614, the middle portion contains four layers of containers which are of different size or dimension of those in the portion 606, each of the four layers being identified by reference numerals 616 through 622. The upper portion 610 has a single layer of container 624 located on top of this portion are various individual items 626 that are intended to remain free standing and easily accessible.

Each of the portions 606, 608 and 610, and the items 26 are to be distributed to separate destinations and therefore require specific patterns of tape to be applied to those portions in order to secure the load 602 but at the same time enabling each portion to be separated from the other portions without disturbing the tape securing the remainder of the load 602.

With reference to Figure 25, the lower portion 606 is to have a multi-X pattern securing the containers within this portion such that on each face or side of the load there will be two crosses where the tape intersects. Firstly the starting height of the tape and finishing height of the tape must be determined and entered by the operator into the micro processor 108 via the keyboard 114. For example, a datum such as the mid section of the height of pallet 700 on which the load is stacked may be used as the starting height and the finishing height being at 730 which is where the tape is applied horizontally in a banding fashion around the top layer 612 of boxes within the lower portion 606.

Initially the operator applies a portion of the tape, for example at the starting position at 732 on the pallet, then start the operation of the wrapping machine 2 which initially applies tape along face 636 as indicated by cycle 1' and the carriage assembly, and therefore the tape dispensing means, moves in an upward direction under the control of the program as indicated on face 38 where the tape is applied to the load in cycle 2'. Generally where the load is square in profile, each quarter revolution of the turntable is sensed and detected by the processor so that it can detect a comer of the load which may necessitate a particular movement up or down or in a stationary position of the carriage assembly. It can be seen that in cycle 4' on face 634 the tape is wrapped along the layer 612 in a horizontal manner and then in cycles on face 636 the carriage assembly descends. At cycles 13' and 14' the tape is applied to the pallet 700. The whole process of creating Xs or cross over points where the tape intersects whereby two crosses are applied to each face of the load, takes seven revolutions on the turntable such that at cycle 28' it has come back to the same comer as the starting position. At this point the program has already been loaded with other parameters that determine the predefined pattern to be applied to the middle portion 608 of the load. Specially here one cross per face has been designated and a starting height maybe determined as being the same height at level 730 and the finishing height being at 742. There will however be an interim height 744 at which horizontal banding of the tape is applied to the middle portion 608.

All of these heights are programmed or loaded into the program into memory so that the program can execute the particular movements of the carriage assembly in accordance with the rotation of the turntable and therefore the position of the load. Thus in cycle 29' the tape is applied from the comer shared by faces 634 and 636 and goes up to level 742 at the comer edge shared by faces 636 and 638. The next cycle 30' on face 638 is horizontal and then on face 640 the next cycle is cycle 31 ' whereby tape is applied downwardly such that the carriage and tape dispenser move downwardly until the level 644 is reached and whereby on face 634 the cycle 632 is such that tape is applied in a horizontal manner. Four further revolutions are required to create one X pattern for securing the middle portion 608 of the load. When the portion 608 needs to be separated from the portion 606 at a particular destination it is a simple matter of cutting the tape at 750 in order to achieveJhis. The tape is now positioned at the comer or edge at faces 634 and 636 at level 742 ready to complete the final securing of the top layer 624. In this situation end height at 752 is programmed such that during cycle 49' the tape is applied in an upward direction along face 636 and then once it reaches face 638 a horizontal banding is undertaken through cycles 50', 51', 52' and 53'. Further cycles may be implemented if required. To detach this portion 610 from portion 608 it is a simple matter of cutting the tape at 654.

In order to secure the items 626 to the top of the load generally a top cap or sheet of plastic material is placed over each of the sides of the top of the load and then banded in a similar fashion as described with reference to the securing of the upper layer or portion 610. To remove the plastic material it is simply a matter of either cutting through it or removing the banding securing the plastic sheet to the top of the load.

A looping pattern may be applied to the comers 661 to 663 of the load 602. As many looping cycles may be used and this also applies to application of the multi-X and banding techniques in that any number of revolutions of the turntable and therefore the load may be used in applying various numbers of the predefined pattern to a particular portion of the load. It is to be noted that the whole process described with reference to Figures 24 and 25 may take place in one complete operation of the load wrapping machine such that the tape is continuously paid out from the tape dispensing means and applied to the load in a single ran in accordance with the computer program stored in the memory means.

Separation of each of the portions 606, 608 and 610 and the items 626 is easily achieved by cutting the tape at a designated location whereby each of these portions and the items 626 are delivered to separate destinations. The present invention overcomes the difficulties associated with breathability of produce, especially produce that requires cooling whereby the application of tape allows significant areas for air to flow through over the produce when it is wrapped by the tape in a load on a pallet. Furthermore it overcomes the disadvantage of having to double handle a particular load in that it need not be set aside on the pallet and cooled in one particular location and then moved to be taped or secured. By use of the present invention the tape may be applied directly to the pallet as the produce is stacked and then transported to its intended destination. By using tape rather than stretch film enormous reduction in waste material is achieved. This saves on costs for particular industries where a charge is made per weight or volume for removal of waste material. In other words, there is substantially less volume or weight contained by waste tape as there is in relation to waste film. Every pallet load will present different problems and requirements for containment depending on its shape, height, weight, length and breadth and depending on the physical properties of individual units contained in the load. The present invention enables a variety of wrapping patterns to be applied to different loads, or to different portions of a same load, to achieve a desired result in the load containment.

It will also be appreciated that various modifications and alterations may be made to the prefened embodiments above, without departing from the scope and spirit of the present invention.

Claims

1. A system for wrapping a load with a tape in a predefined manner, the system including: a turntable for supporting the load, turntable drive means for causing rotational movement of the turntable, a mast assembly, a carriage assembly mounted to the mast assembly, carriage assembly drive means for driving the carriage assembly along the mast assembly, tape dispensing means attached to the carriage assembly, and a control system for controlling operation of the carriage assembly drive means and the turntable drive means, the control system including processing means and associated memory means for storing program instructions to cause the control system to displace the carriage assembly along the mast so that, as turntable is rotated, the tape is applied to secure the load in one or more predefined patterns.

2. A system according to claim 1, wherein the program instructions cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to at least a portion of the load in a series of spirals where the tape crosses itself at multiple positions on one or more faces of the load.

3. A system according to claim 2, wherein the tape crossing positions are calculated by the processing means from crossing number data characterising the number of desired crossing positions on the one or more load faces.

4. A system according to claim 2, wherein the tape crossing positions are calculated by the processing means from crossing position data characterising the position of each desired crossing position on the one or more load faces.

5. A system according to either one of claims 3 or 4, wherein the load portion includes a plurality of layers, and the tape crosses itself once at each layer.

6. A system according to any one of claims 2 to 5, wherein the tape is also applied about the load portion in a first band at an uppermost tape crossing point.

7. A system according to any one of claims 2 to 6, wherein the tape is also applied about the load portion in a second band at a lowermost position.

8. A system according to claim 7, wherein the load includes one or more articles supported by a pallet, and the second band in applied about the pallet.

9. A system according to any one of claims 6 to 8, wherein the band application positions are calculated by the processing means from band position data.

10. A system according to any one of claims 2 to 9, wherein the tape is also applied multiple times about an uppermost portion of the load.

11. A system according to claim 10, wherein the multiple applications of the tape about an uppermost portion of the load are offset from each other.

12. A system according to any one of claims 2 to 11, wherein the tape is also applied multiple times about an lowermost portion of the load.

13. A system according to claim 12, wherein the multiple applications of the tape about an lowermost portion of the load are offset from each other.

14. A system according to any one or the preceding claims, wherein the program instructions cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to at least a portion of the load in a plurality of bands about the load.

15. A system according to claim 14, wherein the tape fleets between adjacent bands.

16. A system according to either one of claims 14 or 15, wherein the band application positions are calculated by the processing means from band position data.

17. A system according to any one of the preceding claims, wherein the program instructions cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to at least an uppermost portion of the load from a first face across the top of the load to a second face.

18. A system according to any one of the preceding claims, wherein the program instructions cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to at least a portion of the load in accordance with load dimension data.

19. A system according to any one claims 3, 4, 9, 16 or 18, wherein the data is input to the processing means from a data entry device.

20. A computer program for use in system for wrapping a load with a tape in a predefined manner, the system including a turntable for supporting the load, turntable drive means for causing rotational movement of the turntable, a mast assembly, a carriage assembly mounted to the mast assembly, carriage assembly drive means for driving the carriage assembly along the mast assembly, tape dispensing means attached to the carriage assembly, and a control system for controlling operation of the carriage assembly drive means and the turntable drive means, the control system including processing means and associated memory means for storing the computer program, the computer program including program instructions to cause the control system to displace the carriage assembly along the mast so that, as turntable is rotated, the tape is applied to secure the load in one or more predefined patterns.

21. A computer program according to claim 20, wherein the program instructions cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to at least a portion of the load in a series of spirals where the tape crosses itself at multiple positions on one or more faces of the load.

22. A computer program according to claim 21, wherein the programming instructions cause the processing means to calculate tape crossing positions from crossing number data characterising the number of desired crossing positions on the one or more load faces.

23. A computer program according to claim 21, wherein the programming instructions cause the processing means to calculate the tape crossing positions from crossing position data characterising the position of each desired crossing position on the one or more load faces.

24. A computer program according to either one of claims 22 or 23, wherein the load portion includes a plurality of layers, and the tape crosses itself once at each layer.

25. A computer program according to any one of claims 21 to 24, wherein the tape is also applied about the load portion in a first band at an uppermost tape crossing point.

26. A computer program according to any one of claims 21 to 25, wherein the tape is also applied about the load portion in a second band at a lowermost position.

27. A computer program according to claim 26, wherein the load includes one or more articles supported by a pallet, and the second band in applied about the pallet.

28. A computer program according to any one of claims 25 to 27, wherein the program instmctions cause the processing means to calculate band application positions from band position data.

29. A computer program according to any one of claims 21 to 28, wherein the tape is also applied multiple times about an uppermost portion of the load.

30. A computer program according to claim 29, wherein the multiple applications of the tape about an uppermost portion of the load are offset from each other.

31. A computer program according to any one of claims 21 to 30, wherein the tape is also applied multiple times about an lowermost portion of the load.

32. A computer program according to claim 31, wherein the multiple applications of the tape about an lowermost portion of the load are offset from each other.

33. A computer program according to any one or the preceding claims, wherein the program instmctions cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to at least a portion of the load in a plurality of bands about the load.

34. A computer program according to claim 33, wherein the tape fleets between adjacent bands.

35. A computer program according to either one of claims 33 or 34, wherein the program instmctions cause the processing means to calculate band application positions from band position data.

36. A computer program according to any one of the preceding claims, wherein the program instructions cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to at least an uppermost portion of the load from a first face across the top of the load to a second face.

37. A computer program according to any one of the preceding claims, wherein the program instructions cause the control system to displace the carriage assembly and rotate the turntable so as to apply the tape to at least a portion of the load in accordance with load dimension data.

38. A computer program according to any one claims 22, 23, 28, 36 or 37, wherein the data is input to the processing means from a data entry device.