Dunnage system and method using a coil accumulator
10864696 ยท 2020-12-15
Assignee
Inventors
Cpc classification
B65H54/585
PERFORMING OPERATIONS; TRANSPORTING
B65H2301/418523
PERFORMING OPERATIONS; TRANSPORTING
B65H2405/421
PERFORMING OPERATIONS; TRANSPORTING
B31D2205/0064
PERFORMING OPERATIONS; TRANSPORTING
B65H2301/41447
PERFORMING OPERATIONS; TRANSPORTING
B31D5/006
PERFORMING OPERATIONS; TRANSPORTING
B65H19/29
PERFORMING OPERATIONS; TRANSPORTING
B65H19/2292
PERFORMING OPERATIONS; TRANSPORTING
International classification
B31D5/00
PERFORMING OPERATIONS; TRANSPORTING
B65H19/29
PERFORMING OPERATIONS; TRANSPORTING
B65H54/58
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A dunnage production system for producing coiled strips of dunnage includes a supply of strip-like dunnage, a coiler adjacent the supply and rotatable about a coiling axis for coiling a strip of the strip-like dunnage into a coil having a coiled configuration, and a tube aligned with the coiling axis. The tube has an internal diameter sized to receive the coil from the coiler in a discharge direction parallel to the coiling axis. The tube is capable of holding at least one coil in its coiled configuration until it is removed from the tube.
Claims
1. A system for producing a coiled strip of dunnage, comprising: a supply of strip-like dunnage; a coiler adjacent the supply, the coiler including a coiling mechanism configured to engage the strip of dunnage, and the coiling mechanism is rotatable about a coiling axis for coiling a strip of dunnage from the supply into a coiled configuration; and a tube aligned with the coiling axis having an internal diameter sized to receive coils from the coiler in a discharge direction parallel to the coiling axis, the tube having a length dimension parallel to the coiling axis that is greater than a length of the coiling mechanism parallel to the coiling axis, whereby the tube is capable of receiving and holding at least one coiled strip of dunnage in the coiled configuration.
2. A system as set forth in claim 1, wherein an end of the tube at least partially surrounds the coiler to restrict access to the coiler.
3. A system as set forth in claim 1, further comprising a tube slide for moving the tube away from the coiler to improve access to the coiler, where the end of the tube is moveable between an operating position adjacent the coiler to a service position removed from the operating position.
4. A system as set forth in claim 3, further comprising a coiler lock preventing displacement of the coiler when the tube is not in the operating position.
5. A system as set forth in claim 3, further comprising at least one sensor detecting when the tube has moved away from the operating position.
6. A system as set forth in claim 1, further comprising a pusher moveable between a coiling position and a displaced position removed from the coiling position to axially displace the coiled strip of dunnage from the coiler into the tube.
7. A system as set forth in claim 6, further comprising a pusher actuator connected to the pusher to move the pusher from the coiling position to the displaced position.
8. A system as set forth in claim 7, further comprising at least one sensor that detects when a strip of dunnage has been coiled, wherein the pusher is actuated when a strip of dunnage has been coiled.
9. A system as set forth in claim 6, wherein the pusher is moveable along an axis axially aligned with the coiling axis.
10. A system as set forth in claim 6, wherein the pusher is moveable through at least a portion of the tube.
11. A system as set forth in claim 6, further comprising a pusher slide located externally to the tube, wherein the pusher moves along the pusher slide between the coiling position and the displaced position.
12. A system as set forth in claim 1, further comprising at least one sensor for detecting when the coiled strip of dunnage has been axially displaced into the tube.
13. A system as set forth in claim 12, wherein the at least one sensor includes a sensor for detecting when a predetermined number of coiled strips of dunnage are being held in the tube.
14. A system as set forth in claim 1, further comprising at least one sensor for detecting when a coiled strip of dunnage is removed from the tube.
15. A system as set forth in claim 14, further comprising a coiler controller in communication with the at least one sensor to activate the coiler when the sensor indicates that the tube has capacity to receive a coiled strip of dunnage.
16. The system as set forth in claim 1, further comprising a converter operable to convert a sheet stock material into the supply of strip-like dunnage, the converter having an outlet for dispensing a strip of the strip-like dunnage in a downstream direction towards the coiler.
17. A system as set forth in claim 16, further comprising a converter controller in communication with at least one sensor to activate the converter when the sensor indicates the tube has capacity to receive a coiled strip of dunnage.
18. A system as set forth in claim 16, wherein the sheet stock material is paper.
19. A system as set forth in claim 1, wherein the tube includes a coil tray adjacent the tube in the discharge direction for further holding and conveying of the coiled strip of dunnage from the tube.
20. A system as set forth in claim 19, wherein the coil tray is an axially extending portion of the tube remote from the coiler.
21. A system as set forth in claim 1, wherein the tube has a cylindrical wall defining the diameter of the tube.
22. A method of producing coiled dunnage, comprising the following steps: coiling a strip of dunnage about a coiling axis; and axially displacing the coiled strip of dunnage into a tube to hold the coiled strip of dunnage in a coiled configuration.
23. The method as set forth in claim 22, further comprising detecting when the coiled strip of dunnage has been axially displaced.
24. The method as set forth in claim 22, further comprising detecting when a coiled strip of dunnage is removed from the tube.
25. The method as set forth in claim 22, further comprising coiling a strip of dunnage in response to a signal indicating that a coiled strip of dunnage has been removed from the tube.
26. The method as set forth in claim 22, further comprising detecting when a predetermined number of coiled strips of dunnage are being held in the tube.
27. The method as set forth in claim 22, further comprising controlling a converter operable to convert a sheet stock material into the strip-like dunnage in response to a signal indicating that the tube has capacity to receive a coiled strip of dunnage.
28. The method as set forth in claim 22, further comprising controlling the coiling of the strip of dunnage in response to a signal indicating that the tube has capacity to receive a coiled strip of dunnage.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(17) Referring now to the drawings in detail, and initially to
(18) An exemplary system 20 for producing a coiled strip of dunnage includes a supply of strip-like dunnage, such as a converter 26 operable to convert a sheet stock material 28 into a strip of relatively less dense dunnage 29, and a coiler 30 operable to coil the strip of dunnage 29 from the supply into a coiled configuration. Other types of dunnage and dunnage converters may be used, including other types of paper dunnage converters and plastic air pillow converters. The strip of dunnage is received by the coiler 30, which is positioned downstream of the converter 26 or other supply, to roll or wind the strip of dunnage into the coiled configuration. The finished coil is then displaced from the coiler 30 and moved into the tube 24 to hold it in its coiled configuration.
(19) Exemplary dunnage converters are shown and described in U.S. Pat. No. 5,123,889 and in published International Patent Application No. PCT/US2001/018678, both of which are incorporated herein by reference. The illustrated converter 26 includes a conversion assembly 32 that pulls the sheet stock material 28 in a downstream direction and advances the stock material 28 from a supply through the converter 26, which converts the stock material 28 into a relatively lower density strip of dunnage. The supply of sheet stock material 28 generally is provided in a compact configuration, such as a roll of stock material or a generally rectangular stack of fan-folded stock material. The sheet stock material 28 may be paper, such as kraft paper, although the system and method provided by the invention could use other types of sheet material, such as plastic sheet material convertable into a strip of air-filled bags. Additionally, the sheet stock material 28 may be single ply or have multiple plies.
(20) The illustrated conversion assembly 32 includes a feeding/connecting assembly 34 that pulls the sheet stock material 28 through a forming assembly 36. The forming assembly 36 randomly crumples the sheet material and inwardly guides lateral edges of the sheet material before the feeding/connecting assembly 34 connects overlapping layers of the crumpled sheet so that the strip of dunnage holds its crumpled strip-like shape. The converter 26 also includes a severing assembly 38 for severing the completed strip of dunnage 29, once a desired length has been produced. The strip of dunnage 29 exits the converter through a discharge chute 40 which forms the outlet of the converter 26.
(21) A coiler 30 is positioned downstream of the converter 26 to receive the strip of dunnage from the outlet 40, as shown in
(22) In the illustrated system 20, the coil ejector includes a moveable pusher 48 for axially displacing the coiled strip of dunnage from the coiler 30 into the tube 24 in a discharge direction. The discharge direction is parallel to the coiling axis and transverse to the downstream direction. The pusher 48 is initially in a coiling position near the ends 46 of the coiler forks 44 and the base 48 of the coiler 30 while the coiler 30 is coiling the strip about the coiling axis. After the coiler 30 has coiled the strip, the pusher 48 is moveable to a displaced position removed from the coiling position to axially displace the coiled strip into the tube 24 in the discharge direction. In the illustrated embodiment, the pusher 48 has a disc-shaped body with a circular aperture 50 through which the coiler forks 44 extend as the pusher 48 moves in the discharge direction from the coiling position to the displaced position.
(23) The pusher 48 is moveable between the coiling position and the displaced position by a pusher actuator 52 connected to the pusher 48 to move the pusher 48 in the discharge direction. The pusher actuator 52 moves the pusher 48 along a pusher slide 54 extending in the discharge direction. The disc-shaped body portion of the pusher 48 extends perpendicular to the pusher slide 54. A bracket 56 fixed to the disk body of the pusher 48 supports the pusher 48 for movement along the pusher slide 54. The illustrated pusher slide 54 is located externally to the tube 24 and parallel to the coiling axis, but the pusher 48 may be moveable through at least a portion of the tube 24 or through the entire tube 24.
(24) Referring in addition to
(25) In the illustrated embodiment, the first end 58 of the tube 24 surrounds the coiler 30 as in
(26) The illustrated tube 24 has a strip-receiving passage 62 at the first end 58 of the tube 24, as best shown in
(27) In another exemplary embodiment of the tube 24, the tube 24 may be located adjacent to but spaced from the coiler 30 along the discharge direction when in the operating position, such that the coiler 30 coils the strip of dunnage outside of the tube 24. After completion of the coiled strip, the pusher 48 pushes the coiled strip of dunnage into the first end 58 of the tube 24 in the discharge direction. As more strips are coiled and pushed into the tube 24, the strips at the first end 58 of the tube 24 are pushed towards the second end 60 of the tube 24 by the coil being displaced into the first end 58 of the tube 24. The tube 24 is elongated to hold a predetermined number of coiled strips, allowing a plurality of coiled strips to be produced and held in the coiled configuration until they are removed.
(28) The steps of the system 20 producing and holding each of the plurality of coiled strips in their coiled configuration are shown in
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(30) The system 20 may include control elements that facilitate producing and holding a plurality of coiled strips of dunnage in the coiled configuration. As shown in
(31) The control elements further may include a sensor 72 that detects when a strip of dunnage has been coiled by the coiler 30, as shown in
(32) When the system 20 is not in operation, or at rest, the tube 24 typically has a service position removed from its operating position to allow maintenance to be performed on the coiler 30 or other components of the system 20 that may be normally inaccessible due to the position of the tube 24.
(33) The illustrated tube slide 74 is located outside the tube 24 and parallel to the coiling axis, as best shown in
(34) Referring in addition to
(35) The coiler arm lock 78 thus improves upon previous coiler arm locks by providing an additional locking function. Previous coiler arm locks were used to secure the coiler forks 44 in a locked position and could be unlocked at any time. The coiler arm lock 78 provided by the invention will not unlock until the sensor 80 indicates that the tube 24 is removed from the coiler 30. The system 20 also may include a secondary coiler arm lock 81 similar to previously coiler arm locks. Thus, when the sensor 80 indicates that the tube 24 is removed from the coiler 30, the coiler arm lock 78 automatically unlocks and the secondary coiler arm lock 81 also has to be unlocked in the conventional manner, providing a backup.
(36) Aside from maintenance, the system 20 can be locked during transportation of the system 20. As shown in
(37) The exemplary system 20 shown in
(38) An exemplary coil tray 184 is formed as an integral extension of the tube 124 shown in
(39) The present invention also provides a method of producing coiled dunnage that includes the steps of (1) coiling a strip of dunnage about a coiling axis, and (2) axially displacing the coiled strip of dunnage into a tube to hold the coiled strip of dunnage in a coiled configuration. The method further may include the steps of (3) detecting when the coiled strip of dunnage has been axially displaced, (4) detecting when a predetermined number of coiled strips of dunnage are being held in the tube, and (5) detecting when a coiled strip of dunnage is removed from the tube. The method further may include the step of (6) coiling a strip of dunnage in response to a signal indicating that a coiled strip of dunnage has been removed from the tube. The method further may include the steps of (7) controlling a converter operable to convert a sheet stock material into the strip of dunnage, and (8) controlling the coiling of the strip of dunnage in response to a signal indicating that the tube has capacity to receive a coiled strip of dunnage.
(40) In summary, the present invention provides a dunnage production system 20 for producing coiled strips of dunnage that includes a supply of strip-like dunnage 29, a coiler 30 adjacent the supply 29 and rotatable about a coiling axis for coiling a strip of the strip-like dunnage 29 into a coil having a coiled configuration, and a tube 24 aligned with the coiling axis. The tube 24 has an internal diameter sized to receive coils from the coiler 30 in a discharge direction parallel to the coiling axis. The tube 24 is capable of holding at least one coiled strip of dunnage in its coiled configuration until it is removed from the tube 24.
(41) Although the invention has been shown and described with respect to certain embodiments, equivalent alterations and modifications will occur to others skilled in the art upon reading and understanding this specification and the annexed drawings. In particular regard to the various functions performed by the above described integers (components, assemblies, devices, compositions, etc.), the terms (including a reference to a means) used to describe such integers are intended to correspond, unless otherwise indicated, to any integer which performs the specified function of the described integer (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.