Assembly, strap guiding device and method for providing a bulky item with a strap

Abstract

An assembly for applying a strap around the outer circumferential surface of a bulky item. The assembly comprises a binding zone configured to receive the bulky item; a channel defined along a guiding surface of a strap guiding device that surrounds the binding zone and is configured to guide strap material around the bulky item; and a binding apparatus with a binding head for delivering the strap material to the channel and for fastening a first end of the strap material to a second end of the strap material to form the strap. The channel has two channel ends that define an opening through which the binding head can pass. The opening in the channel can be rotated to allow placement of the bulky item into the binding zone.

Claims

1. An assembly for applying a strap around the outer circumferential surface of a bulky item, the assembly comprising: a binding zone configured to receive the bulky item; a strap guiding device with a channel support supporting a guiding surface, wherein a channel is defined along the guiding surface, the channel surrounding the binding zone and configured to guide strap material around the bulky item; and a binding apparatus with a binding head for delivering the strap material to the channel and for fastening a first end of the strap material to a second end of the strap material to form the strap; wherein the channel has two channel ends that define an opening through which the binding head can pass and wherein the binding apparatus can move the binding head to at least a first position in alignment with the channel from which the binding head can shoot the strap material into the channel, a second position inside the binding zone where the binding head can fasten the strap, and a third position outside of the binding zone, and wherein the opening in the channel can be rotated to allow placement of the bulky item into the binding zone.

2. The assembly according to claim 1, wherein the strap guiding device further comprises: a frame for rotatably supporting the channel support; and a drive system for rotating the channel support.

3. The assembly according to claim 1, wherein the opening in the channel can be rotated between at least a first position wherein the bulky item can be placed within the strap guiding device and a second position wherein the opening in the channel is facing the binding apparatus.

4. The assembly according to claim 1, wherein the binding head is configured to make a movement along a non-straight trajectory.

5. The assembly according to claim 1, wherein the assembly comprises at least two separate channels configured to be used alternatingly in combination with the binding head of the binding apparatus.

6. The assembly according to claim 1, wherein the binding apparatus comprises a channel guide segment, configured to span or close the opening between the channel ends.

7. The assembly according to claim 6, wherein the channel guide segment has two segment ends and the channel guide segment is configured to provide for a gap between each of the channel ends and the segment ends when the channel guide segment spans the opening between the channel ends, wherein the gaps may have a size of maximum 15 mm.

8. The assembly according to claim 7, wherein the channel is defined along a guiding surface that continues uninterruptedly between the channel ends.

9. The assembly according to claim 8, wherein the channel guide segment has two segment ends and a guiding surface between the two segment ends, wherein the guiding surface at the channel ends is non-planar and wherein the segment guiding surface at the segment ends is complementary in shape to the guiding surface.

10. The assembly according to claim 6, wherein the channel guide segment is straight or arc shaped.

11. The assembly according to claim 6, wherein the binding head has two sides, each side facing one of the channel ends, and wherein the channel guide segment extends from one or both sides of the binding head.

12.-20. (canceled)

21. A strap guiding device for guiding a strap around the outer circumferential surface of a bulky item, the strap guiding device comprising: a channel at least partially circumferentially extending around a binding zone for the bulky item, the channel having two channel ends that define an opening through which a binding head of a binding apparatus can pass, wherein the channel ends provide access for a binding apparatus for guiding a strap through the channel; a channel support supporting a guiding surface, wherein the channel is defined along the guiding surface; a frame for rotatably supporting the channel support; and a drive system for rotating the guiding surface around a center of a substantially circular path, wherein the opening in the channel can be rotated between at least a first position wherein the bulky item can be placed within the strap guiding device and a second position wherein the opening in the channel is facing the binding apparatus.

22. The strap guiding device according to claim 21, further comprising a plurality of channel guide portions, wherein the plurality of channel guide portions are supported by the channel support and wherein the plurality of channel guide portions together with the guiding surface define the circumferentially extending channel, wherein the channel guide portions at least partially enclose the channel.

23. The strap guiding device according to claim 22, wherein each channel guide portion is provided with a retention system for selectively retaining the strap within the channel guide portion.

24. The strap guiding device according to any of claim 21, wherein the guiding surface continues uninterruptedly between the channel ends.

25. (canceled)

26. A method for providing a bulky item with a strap, the method comprising: arranging a bulky item on a support within a strap guiding device, wherein the strap guiding device comprises: a channel at least partially circumferentially extending around a binding zone for the bulky item, the channel having two channel ends that define an opening through which a binding head of a binding apparatus can pass, wherein the channel ends provide access for a binding apparatus for guiding a strap through the channel, a channel support supporting a guiding surface, wherein the channel is defined along the guiding surface; a frame for rotatably supporting the channel support; and a drive system for rotating the guiding surface around a center of a substantially circular path, wherein the opening in the channel can be rotated between at least a first position wherein the bulky item can be placed within the strap guiding device and a second position wherein the opening in the channel is facing the binding apparatus; providing a binding apparatus with a binding head according to claim 25; controlling the binding apparatus to move the binding head near the opening in the channel and arrange the binding head to at least partially enter through the opening in the channel; spanning the opening in the channel to provide an uninterrupted channel; guiding a strap through the circumferentially extending channel using the binding apparatus; receiving a strap end of the strap in the binding head; and fastening the strap using the binding head.

27. The method according to claim 26, further comprising moving the binding head of the binding apparatus to a position outside of the binding zone.

28. The method according to claim 26, wherein spanning the opening in the channel comprises controlling the binding apparatus to hold a channel guide segment in the opening.

29. The method according to claim 26, wherein fastening the strap comprises engaging an outer surface of the bulky item with the binding head; tightening the strap around the bulky item using the binding head; and connecting the strap end to a second strap end connected to the strap supply.

30. The method according to claim 26, wherein the method further comprises rotating the channel to a position wherein the opening in the channel is facing the binding apparatus; and/or rotating the channel to a position wherein the bulky item can be placed within the strap guiding device.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0049] Embodiments will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts. In the drawings, like numerals designate like elements. Multiple instances of an element may each include separate letters appended to the reference number. For example, two instances of a particular element 20 may be labeled as 20a and 20b. The reference number may be used without an appended letter (e.g. 20) to generally refer to an unspecified instance or to all instances of that element, while the reference number will include an appended letter (e.g. 20a) to refer to a specific instance of the element.

[0050] FIG. 1A schematically shows an assembly for providing a bulky item with a strap according to a first embodiment of the invention.

[0051] FIG. 1B shows a cross-sectional view of the channel support and the channel as indicated in FIG. 1A.

[0052] FIG. 2A shows a detail of the binding head on the binding apparatus in the assembly of FIG. 1A.

[0053] FIG. 2B shows a cross-sectional view of the channel guide segment as indicated in FIG. 2A.

[0054] FIG. 3A-3G schematically illustrate stages of a method for providing a bulky item with a strap using the assembly in FIG. 1.

[0055] FIG. 4 shows a detail of the transition between the guiding surface of the strap guiding device and the guiding surface of the channel guide segment according to a first embodiment.

[0056] FIG. 5 shows a detail of the transition between the guiding surface of the strap guiding device and the guiding surface of the channel guide segment according to another embodiment.

[0057] FIG. 6 shows a detail of the transition between the guiding surface of the strap guiding device and the guiding surface of the channel guide segment according to yet another embodiment.

[0058] FIG. 7 shows an assembly for providing a plurality of bulky items with a strap according to a further embodiment of the invention.

[0059] The figures are meant for illustrative purposes only, and do not serve as restriction of the scope or the protection as laid down by the claims.

DESCRIPTION OF EMBODIMENTS

[0060] The following is a description of certain embodiments of the invention, given by way of example only and with reference to the figures.

[0061] FIG. 1A schematically shows an axial view of a first embodiment of an assembly 1 for providing a bulky item with a strap around its outer circumferential surface. The assembly 1 comprises a strap guiding device 10, a binding apparatus 2 with a binding head 3, channel guide segment 15 and strap accumulator 6, a support 4 for supporting a bulky item 5 (not shown), and a strap dispenser 9. The assembly 1 is arranged on a floor 7 with a pit 71 at the position of the support 4.

[0062] The strap guiding device 10 is arranged on the floor 7 and has a channel support 11, a frame 12, a drive system 13 and a plurality of channel guide portions 16 defining a circumferentially extending channel 17. The channel support 11 carries the plurality of channel guide portions 16. Each channel guide portion 16 has a first portion end 26 and a second portion end 27. The plurality of channel guide portions 16 are arranged to form an arc shaped trajectory along a substantially circular path P, wherein the first portion end 26 of a first channel guide portion 16a is adjacent to the second portion end 27 of a second channel guide portion 16b to form the arc shaped trajectory. Each channel guide portion 16 is approximately 38 cm long as measured along the circular path P, yet it will be understood that not all channel guide portions 16 need to have the same length and that the channel guide portions 16 may be shorter or longer. The channel guide portions 16 are placed adjacent to each other, but do not abut. A space between 5 and 10 mm is left between each pair of adjacent channel guide portions 16.

[0063] The plurality of channel guide portions 16 define two exterior portion ends 21a, 21b that define an opening 14. The drive system 13 is configured to rotate the channel support 11 with the plurality of channel guide portions 16 around a center C to move the opening 14 along a substantially circular path P defined by the plurality of channel guide portions 16. The binding zone 80 is defined as the space circumferentially enclosed by the path P.

[0064] The support 4 is a saddle arranged to support a bulky item from below. The saddle 4 has four elevated surfaces 41 (only two are shown) that each can support part of the lower surface of the bulky item. The saddle 4 has an open structure, meaning that there is a passage provided between the four elevated surfaces 41. The passage provides access to the lower surface of a bulky item arranged on the support. The pit 71 in the floor 7 eases the arrangement of the bulky item on the support 4. The pit 71 may for example carry conveyance means that enable the positioning of a bulky item on the support 4. It will be understood that the support 4 may have a different shape or height dependent on the type of bulky item that is to be supported. The support 4 in the depicted embodiment is particularly suited for supporting a roll with metal wound sheets.

[0065] The plurality of channel guide portions 16 together form an arc shape with an arc angle of approximately 280 degrees and a diameter of 2.5 m. The opening 14 near the floor 7 and support 4 is dimensioned to fit around the support 4 and is approximately 1.5 m. It will be understood, however, that the strap guiding device 10 is easily scalable and can be adjusted based on the dimensions of the bulky item that is to be provided with a strap.

[0066] The channel guide segment 15 is also shaped as a circular arc (see FIG. 2A), having an arc angle of slightly less than 80 degrees. The channel guide segment 15 can thereby span the opening 14 in the plurality of channel guide portions 16, without entirely closing it. This enables the binding head 3 with the channel guide segment 15 attached thereto, to easily pass through the opening 14. The channel guide segment 15 is discussed in more detail with reference to FIG. 2A below.

[0067] FIG. 1B illustrates a cross-sectional detail of the channel support 11 and one of the channel guide portions 16 as indicated in FIG. 1A. The channel guide portion 16 has a base 23, a guiding surface 22, and a retention system 50 comprising a retention element 19 with two sides 20 and spring elements 18 to bias the sides 20. Each side 20 of the retention elements is connected to the base 23 using a pair of bolts 28. Here only one bolt 28 is shown. The other side 20 comprises an opening 29 opposite to the bolt 28 to easy assembly.

[0068] The channel support 11 is formed by a circular tube (only partially shown) with a diameter of approximately 100 mm. The tube has been bent to form the arc shape as depicted in FIG. 1A. The base 23 is attached to an outer circumferential surface of the channel support 11. In the depicted embodiment, the base 23 is welded to the channel support 11, yet it will be understood that also mechanical fasteners such as bolts may be used.

[0069] The base 23 is shaped as a tube with an approximately square cross section. The base 23 provides a mounting structure for the guiding surface 22, which is provided at a side of the base 23. Along the guiding surface 22, the channel 17 is defined that can house the strap 8. The guiding surface 22 is smooth and provides little resistance when the binding strap 8 slides along the guiding surface 22. The guiding surface 22 is made of steel and continuous uninterruptedly through the plurality of the channel guide portions 16 between the channel ends 21a, 21b. The base 23 may also continue uninterruptedly through several of the channel guide portions 16, yet may alternatively also be provided as a separate straight profile for each of the channel guide portions 16.

[0070] The retention element 19 has two sides 20 that prevent a strap 8 that is arranged within the channel 17 to unintentionally escape from the channel 17. Each side 20 is approximately 38 cm long and connected to the base 23 using bolts 18,19 (not shown) near the portion ends 26,27, of the respective channel guide portions 16. The spring element 18 enables the sides 20 of the retention element to hinge.

[0071] Each channel guide portion 16 has a similar retention element 19 that is biased by one or more spring elements 18. When a loop of strap material is tightened, the strap 8 may be pulled towards the sides 20 of the retention element 19 and under sufficient force, the tension of the spring element 18 may be overcome to widen the opening between the sides 20 and release the strap 8 from the channel 17. An open position for the retention element 19 is schematically indicated in FIG. 1B using dashed lines.

[0072] The binding apparatus 2 is a robot with a binding head 3 having six degrees of freedom. The first three degrees of freedom allow the binding head 3 to make translation movements in three-dimensional space. A fourth degree of freedom is used to tilt the binding head 3 in the correct position to interact with the strap guiding device 10. A fifth degree of freedom is used to turn the binding apparatus 2 around its own central axis Z and away from the strap guiding device 10 and bulky item 5. This enables the binding head 3 to be provided to an engineer at a position where it is safe to carry out maintenance on the binding head 3, or to carry out repairs in case of a failure of the binding head 3. The sixth degree of freedom is not required to perform the binding action. However, the sixth degree of freedom provides flexibility and can compensate for unprecise alignment of the binding apparatus 2 and the strap guiding device 10. Moreover, this additional degree of freedom is advantageous when carrying out maintenance as it enables positioning the binding head 3 in the best accessible position for an operator or engineer. The binding apparatus 2 further comprises the strap accumulator 6.

[0073] FIG. 2A shows the binding head 3 of the binding apparatus 2. The binding head 3 is provided with a strap intake unit 31, a front side 32, an alignment element 33, a plurality of transport rollers 34, a receiving side 35, a receiving channel 36 and a clamp unit 37. The channel guide segment 15 is defined between the two segment ends 24 and comprises a plurality of channel guide portions 16 extending from both sides 32,36 of the binding head 3.

[0074] At the strap intake unit 31, strap material is provided from the strap accumulator 6 of the binding apparatus 2. The rollers 34, driven by a transport motor (not shown) lead the strap material 8 (indicated schematically) through the binding head 3 and towards the front side 32 where the strap material can enter the channel 17 that extends through the plurality of channel guide portions 16 in the channel guide segment 15 and in the strap guiding device 10. The strap material is guided around the bulky item to form a loop 40 (schematically indicated) and a strap end is received in the receiving channel 36 of the binding head 3 and clamped by the clamp unit 37. The clamp unit 37 can hold the strap end while the loop 40 is tightened. The excess of strap material can be pulled back into the strap accumulator 6 using the transport motor or a separate tensioning motor. Once the loop 40 is sufficiently tight, the clamp unit 37 can connect the ends of the strap material together and cut the loop 40 loose from the supply of strap material to form a closed loop.

[0075] The channel guide segment 15 comprises a plurality of channel guide portions 16 and the receiving channel 36 of the binding head 3. More specifically, three channel guide portions 16 are extending from the front side 32 of the binding head 3 and one channel guide portion 16 is extending from the receiving side 35. It will be understood that in embodiments, the number of channel guide portions 16 may be different. For example, the channel guide segment 15 may also be fully integrated with the binding head 3 and the channel guide segment may therefore in embodiments only comprise a receiving channel and/or an integrally formed channel portion extending from the front side of the channel guide.

[0076] FIG. 2B illustrates a cross-sectional detail of one of the channel guide portions 16. The channel guide portion 16 is formed very similar to the plurality of channel guide portions 16, but due to its shorter length, a channel support 11 is not needed. The channel guide portions 16 are directly connected to a base 23 that extend along the length of three retention elements 19. The channel 17 that extends through the channel guide portions 16 of the strap guiding device 10 can uninterruptedly continue into the channel 17 that extends through the channel guide portions 16 of the channel guide segment 15.

[0077] FIGS. 3A-3G show a method for providing a bulky item 5 with a strap using the assembly 1 in FIG. 1. FIG. 2A illustrates the assembly 1 after a bulky item 5 has been arranged on the support 4. The bulky item 5 is a roll with a metal wound sheet. The roll has a lower surface 51 and an eye 52.

[0078] FIG. 3B illustrates the assembly 1, wherein the drive system 13 of the strap guiding device 10 has been controlled to rotate the channel support 11 with the plurality of channel guide portions 16 around the center C. In this position it is typically not easily possible to remove the bulky item 5 from the support 4 since the floor pit 71 is closed by the strap guiding device 10. The opening 14 has been moved from a first position wherein the bulky item 5 could be easily arranged on the support 4, to a second position wherein the opening 14 faces the binding apparatus 2. In the first position, the opening 14 was provided below the lower surface 51 of the bulky item 5, and in the second position the plurality of channel guide portions 16 are arranged to surround the lower surface of the bulky item 5.

[0079] FIG. 3C illustrates the assembly 1 after the binding apparatus 2 has arranged the channel guide segment 15 between the channel ends 21. The channel guide segment 15 spans the opening 14 and the alignment element 33 of the binding head 3 has entered through the opening 14 into the binding zone. The plurality of channel guide portions 16 and guide segment 15 are arranged to form the uninterrupted channel 17 that extends circumferentially around the bulky item 5.

[0080] FIG. 3D illustrates the assembly after a strap 8 has been guided through the circumferentially extending plurality of channel guide portions 16 to surround the bulky item 5. The strap 8 is made of steel, but it will be understood that other types of strap may also be provided using the assembly. The binding head 3 of the apparatus 2 can easily be replaced to also hold other materials and allow for other methods of connecting. The strap 8 has been guided through the channels 17,17 in the strap guiding device 10 and channel guide segment 15 and received in the receiving channel 36 of the binding head 3 as described in relation to FIG. 2A above.

[0081] FIG. 3E illustrates how the binding head 3 engages the circumferential surface 53 of the bulky item 5. While the binding head 3 is moved towards the surface 53, the tensioning motor pulls back part of the strap material into the accumulator 6. The combination of moving the binding head 3 and tensioning the strap leads to the release of the strap material from the channel 17. The strap material is pulled onto the sides 20 of the retention elements, which open once the tension of the spring elements 18 has been overcome.

[0082] FIG. 3F illustrates how the binding head tightens the strap 8 around the bulky item 5. The accumulator 6 retrieves the excess strap material and the clamp unit 37 of the binding head 3 fastens the strap 8 around the bulky item 5 by joining the strap end to another part of the strap 8.

[0083] FIG. 3G illustrates the assembly 1 after the strap 8 has been provided and the apparatus 2 with binding head 3 has disengaged the bulky item 5. The drive system 13 may now rotate the plurality of channel guide portions 16 back to the first position as depicted in FIG. 2A to enable removal of the bulky item 5 from the support 4.

[0084] In the described embodiment, the guiding surface 22 is smooth and uninterrupted between the channel ends 22. Along the path of the strap, the strap encounters only two transitions in the guiding surface 22, where the first and last channel guide portions 16 connect to the channel guide segment 15. These transitions could cause a malfunctioning when the strap 8 is guided through the channel 17 and by limiting the number of transitions, the likelihood of errors is small.

[0085] In contrast, a bayonet solution as known from the prior art has not only two transitions near the binding head, yet in addition a strap guiding device with a bayonet solution would have two or three transitions at the position where the bayonet is arranged. Consequently, a solution with a bayonet is much more prone to failure than a solution with a rotating plurality of channel guide portions 16, because the strap material is more likely to get blocked at a transition. The strap guiding device 10 with a rotatable channel guide minimizes the number of transitions along the guiding surface 22 and thereby improves the reliability of the strapping process.

[0086] FIG. 4 shows a simplified view of a detail of the transition between the guiding surface 22 of the plurality of channel guide portions 16 and the segment guiding surface 22 of the plurality of channel guide portions 16 of the channel guide segment 15. To avoid or reduce problems in the transition between the two, it is important that the guiding surfaces 22, 22 are sufficiently smooth and have as few interruptions along the surface as possible. In this first embodiment both the channel end 21 and a segment end 24 of the channel guide segment 15 are planar. When the opening 14 between the channel ends 21 is spanned by the channel guide segment 15, a gap 25 of approximately 5 mm remains between the ends 21,24. This small gap 25 is sufficiently large to enable a smooth passage of the binding head 3 with the channel guide segment 15 through the opening 14 between the channel ends 21. However, the gap 25 is also sufficiently small to not cause problems when passing the strap 8 through the channel 17.

[0087] FIGS. 5 and 6 show a detail of an alternative embodiment of a transition between the guiding surfaces 122, 122. In FIG. 4, the channel end 121 is provided with a transverse edge. The segment end 124 is complementary in shape. In FIG. 6 the channel end 221 is provided with a female receiving portion. The segment end 224 is provided with a male portion and is complementary in shape. It can have advantages for the reliability of the strap 8 passing to provide a configuration wherein the ends 121,124 of the channel guide and channel guide segment partially overlap. Since the strap 8 typically is provided with a straight end, this reduces the likelihood that a strap 8 gets blocked at a transition from the channel guide 116, 216 to the channel guide segment 115, 215 or vice versa. In FIGS. 3 to 5, the strap material is passed from the segment guiding surface 22 of the channel guide segment 15 to the guiding surface 22 of the plurality of channel guide portions 16.

[0088] FIG. 7 shows a further embodiment of an assembly 101 according to the invention. The assembly comprises two supports 4a, 4b and two strap guiding devices 110a, 110b, but only one apparatus 102 with a binding head 103. The apparatus 102 is arranged at a position between the two strap guiding devices 110. The apparatus 102 is a robot with six degrees of freedom. Rotation around the robot's own central axis z enables the robot 2 to operate both strap guiding devices 110a, 110b alternately. While a first bulky item 5 is removed and replaced in the first strap guiding device 110a, a second bulky item 5 in the strap guiding device 110b can be strapped by the apparatus 2 and vice versa. Consequently, only one binding apparatus 2 is required instead of two, which can significantly reduce the costs of the strapping process.

[0089] In the foregoing description of the figures, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the scope of the invention as summarized in the attached claims. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, but that the invention will include all embodiments falling within the scope of the appended claims. In particular, combinations of specific features of various aspects of the invention may be made. An aspect of the invention may be further advantageously enhanced by adding a feature that was described in relation to another aspect of the invention.