Automatic Package Wrapping Machine

This invention relates to apparatus for automatically wrapping articles, and more particularly to apparatus for neatly wrapping boxes of arbitrary size.

There are numerous types of automated wrapping machines which have been devised in the past. They are usually suited to a particular purpose, and have their limitations when attempts are made to apply them to other purposes.

For example, the typical wrapping machine found in the supermarket for applying heat-seal film to packages of butchered meat presents a clear face on the top for display of the meat and hides all the gathered ends and spare film on the bottom of the package. The machine works well in the supermarket for wrapping butchered meat, but would not do an adequate job of wrapping gifts.

Another class of machine is available for high speed application of preprinted, precut wrappers to product, such as candy bar wrappers to candy bars. While the finished package is attractive and neatly wrapped, the product is usually of a single size, and the wrappers are precut to accommodate that single size.

Other examples can be given, but it is believed that a machine particularly adapted to neatly wrapping boxes of arbitrary size, such as would be found in a conventional department store environment, has not been available.

The requirements on such a machine are that the finished wrapped package be neatly and attractively completed. Considering that the packages can be of any arbitrary size within limits, the ability to meet that requirement is not straight forward. If it is attempted to meet the requirement by using precut sheets which are large enough to accommodate the largest box, difficulty will be encountered in presenting a neat appearance in the wrapped package for boxes which are smaller than the maximum size.

There can be various definitions of "neat" in a neatly wrapped package. In the present context, it is intended to wrap rectangular boxes where all the corners are square or at right angle. In that context, neatly wrapped, unless the context indicates otherwise, is intended to mean a box which is wrapped so that the covering paper is folded or creased at each of the box edges in such a way that any flaps required for the final folding operation are neat and regular in appearance.

A typical application for such machines is in gift wrapping. In department stores which offer a gift wrapping services, the wrapping is usually done by hand. It is labor intensive, sometimes incapable of keeping up with peak demands, and oftentimes subject to variable quality of finished product. In hand wrapping, whether the individual uses cut sheets or roll paper, the entire operation of trimming the sheet to size, placing the box on the sheet, folding the paper over the box and making the taped or glued attachments is done by hand using sight and with the judgment of the individual exercised at most steps of the process. Skill and judgment are required to reliably produce attractively wrapped packages on a regular basis.

With that in view, it is a general aim of the present invention to provide an automatic machine which is capable of accepting boxes of any arbitrary size within a predetermined range, and wrapping those boxes to produce attractively and neatly wrapped packages.

In accomplishing that aim, it is an object to handle the package with care during the wrapping operation, so that it is not jarred, inverted, dropped or otherwise roughly handled, so that the wrapping machine can be used even with gifts which are fragile and expensive.

A further object of the present invention is to provide such a machine which produces carefully formed angular folds giving the appearance of a hand-wrapped gift.

According to a detailed aspect of the invention, it is an object to provide a package wrapping machine which maximizes throughput by performing the wrapping at a plurality of stations which can operate on different boxes simultaneously.

According to another aspect of the invention in its preferred form, an object is to provide a package wrapping machine which is electronically controlled, which eliminates the need for pneumatic or hydraulic attachments, and which is operated under the control of a microprocessor.

As a further extension of that object, a further objective is to provide programming capability for the microprocessor to allow the ready alteration of the basic functions of the machine under the control of an altered processor program.

Accordingly, the invention provides a package wrapping machine for boxes of arbitrary size. An infeed section includes at least one and preferably a plurality of rolls of wrapping paper mounted to selectively unwind the paper therefrom. An input section of the machine accepts a box of arbitrary size, and determines the dimensions of the box. Programmed cutters cut a sheet of paper from the roll, the sheet having dimensions measured to wrap the box. An adhesive applicator automatically applies adhesive to the box in a position to accept a leading edge of the cut sheet. Wrapping means then attaches the leading edge of the sheet to the adhesive covered portion on the box, wraps the box with the sheet, and attaches the trailing edge of the sheet to the partly wrapped box so that four sides of the box are wrapped, leaving two open ends. Fingers, adhesive applicators and wipers then fold and seal flaps at the two open ends thereby to produce a fully and automatically wrapped box.

These and other objects and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

FIG. 1 is a front elevation of a first embodiment of a package wrapping machine exemplifying the present invention;

FIG. 2 is a partial front elevation of the infeed section of the machine showing the paper supply and paper feed mechanism of the machine of FIG. 1;

FIG. 3A is an enlarged view of a portion of the infeed section of FIG. 2 showing a paper sheet being fed into the machine;

FIG. 3B is a partial view similar to FIG. 3A showing the paper drive engaged with the paper infeed;

FIG. 4 is a partial isometric view showing the adjustment mechanism for the slitters which establish the width of the cut sheet;

FIG. 5 is a partial isometric view of the table of the machine with certain components removed to show the motor drives and lead screws which index the mechanisms which control the box and the sequence of wrapping;

FIG. 6 is a partial schematic view of the measuring and first wrapping station showing a box entering the first station;

FIG. 7 is a plan view corresponding to the box position in FIG. 6;

FIG. 8 is a view of the paper infeed, showing the cut sheet being applied to the leading edge of the box;

FIG. 9 is a partly schematic view showing the box in the first wrapping station with the paper applied to the lead edge, wrapped under the box and about to be wiped along the vertical edge of the box;

FIG. 10 is a schematic view similar to FIG. 9 and showing the wrapping progressing to the top of the box;

FIG. 11 is a view similar to FIG. 10 and showing the machine with the top of the box wrapped and applying glue for securing the trailing edge of the sheet;

FIG. 12 is a partly schematic view similar to FIG. 11 and showing the cut sheet wiped into position on the box;

FIG. 13 is a partly schematic view showing the elements of a glue applicator used in a first embodiment of the present invention;

FIG. 14 is a partly schematic view in isometric showing the partly wrapped box being transferred to the second wrapping station;

FIG. 15 is a view similar to FIG. 14 showing the box in the second wrapping station and rotated for folding and fixing the flaps on one of the ends thereof;

FIG. 16 is a view similar to FIG. 15 and showing an overhead box control conveyor being moved into position over the box;

FIG. 17 is a view similar to FIG. 16 showing fingers, wipers and gluers about to be applied to the end flaps of the box;

FIG. 18 is a diagrammatic illustration showing the fingers of FIG. 17 folding two of the flaps on the end of the box;

FIG. 19 is a schematic view showing the adhesive applicator applying adhesive to the end prior to sealing of the flaps;

FIG. 20 is an isometric schematic view showing the folding of the lower flap on the end of the box;

FIG. 21 is an isometric view similar to FIG. 20 showing the wiper sealing the upper flap on the same edge of the box;

FIG. 22 is an isometric view showing the ejection of a completely wrapped box from the package wrapping machine;

FIG. 23 is a plan view showing an adhesive applicator currently used in the preferred embodiment of the present invention;

FIG. 24 is an elevation showing the applicator of FIG. 23 mounted in the apparatus of FIG. 1 for applying adhesive to the box;

FIG. 25 is a block diagram illustrating a computer control system for the wrapping machine of FIG. 1;

FIGS. 26A-26B and 27A-27B are flow charts illustrating a sequence of steps for the control system of FIG. 25 in causing the package wrapping machine of FIG. 1 to perform the functions described herein.

While the invention is susceptible of various modifications and alternative constructions, certain illustrated embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions and equivalents falling within the spirit and scope of the invention as defined by the appended claims.

As shown in the drawings for purposes of illustration, the invention is embodied in a package wrapping machine 30 suitable for gift wrapping, and sometimes referred to herein as gift wrapping machine. The machine 30 is capable of accepting a box of arbitrary size, determining the dimensions of the box, withdrawing from a paper supply 31 a sheet of paper cut to an appropriate computed dimension to wrap the box, then advancing the sheet of paper and box into a wrapping station to wrap the box in the paper and tuck and secure the flaps to produce a completely gift wrapped box.

FIG. 1 shows the elements of a first embodiment of package wrapping machine 30 as comprising an infeed section 31 having a plurality of rolls of paper, preferably of different designs, widths or textures, and selectable for wrapping a particular box. The illustrated embodiment shows four rolls 32-35 of paper, each having a free end held between an associated pair of nip rollers 36-39. A paper infeed generally indicated at 40 supports the paper as it is withdrawn from the roll, and has a feed end 41 near an operative plane of the wrapping machine.

A box to be wrapped is advanced into a first station 40a by means of a computer controlled pusher assembly 43 which cooperates with a centering and measuring apparatus 44 intended to determine the three dimensions of the box, i.e., its length, its width and its height. It is these measurements which are used to determine the size of the sheet which is cut from the paper supply. When the box is in the operative position in the first station, adhesive is applied along one edge thereof, and the leading edge of the paper is advanced from the feed end 41 of the paper feed 40 to be secured to the box with the adhesive. A wiper assembly generally indicated at 150 then wraps the paper around four sides of the box, ultimately securing the trailing edge over the leading edge. Wrapping four sides of the box in this way is sometimes referred to herein as overwrapping, neatly folding the paper over four parallel edges of the box. Thereupon, a further pusher mechanism 45 moves the box into a second wrapping station generally indicated at 46. In the illustrated embodiment, the wrapping station 46 includes a turntable generally indicated at 47 which presents the unwrapped ends of the box to a flap-folding and fixing assembly generally indicated at 47a. The flap-folding and fixing assembly tucks the flaps on the end, applies adhesive by means of an adhesive applicator 48, and utilizes a wiper mechanism 49 to secure the flaps. As will be described in greater detail below, the flap-folding and fixing assembly folds the paper along the four edges of the end face of the box to create flaps which are then sealed to prevent a neatly folded end face. In the illustrated embodiment, each edge of the box is done independently, and the turntable 47 rotates the box 180.degree. after the first set of flaps are folded and fixed, whereupon the operation is repeated to fold and fix the second set of flaps. The turntable 47 thereupon rotates 90.degree. and delivers the box from the wrapping machine fully wrapped.

With that general description of the package wrapping machine, and an indication of significant functional elements, attention will now be directed to the particular stations in the exemplary embodiment, for a further description of the mechanisms which accomplish the generally described functions.

FIG. 1 shows the four paper supply rolls 32-35 as being fixed in a carriage 60 which can be translated in a vertical direction on sliding blocks 61, 62. The vertical height of the carriage 60 is controlled by means of an electronic drive 63 operating through a chain drive 64, 65 secured to the carriage. Rotation of the motor 63 in one direction or the other serves to raise or lower the carriage 60. The carriage 60 can be raised for loading new rolls of paper onto the hubs. In addition, the carriage is automatically positioned to bring one of the rolls into an operative position. In the illustration of FIG. 1, the roll 32 is shown in the operative position in which the nip rollers 36 associated with the roll 32 are juxtaposed to the entrance end 67 of the paper feed 40. The carriage 60 can be lowered to bring any of the other three sets of nip rollers 37, 38 or 39 into the operative position adjacent the infeed 67 of the paper feed 40.

At the start of a cycle, the electronic controller, which will be described below, selects one of the paper types for wrapping the particular box, and operates the elevator drive 63 to bring the nip rollers 36-39 of the selected roll 32-35 into the operative position. A sheet of paper is then cut from the supply roll, with the dimensions of the sheet matching the dimensions of the package to be wrapped.

It was noted above, that the box to be wrapped can be of arbitrary size. Measuring means are provided in the first station 40a for determining the dimensions of the box, and those mechanisms will be described below. Suffice it to say for the moment that the dimensions have been determined and are available to the processor for use in measuring and cutting a sheet of appropriate size from the supply roll.

In practicing the invention, both the length and width of the sheet are tailored to the dimensions of the box of arbitrary size to be wrapped. By way of definition and not limitation, and solely for the purpose of facilitating description of the machine, the length of the sheet will be referred to as that dimension capable of overwrapping the four sides of the box commonly called its top, its bottom, and two long sides. The corresponding dimensions of the box will be called its length (see the dimension L in FIG. 14) and its height (see the dimension H in FIG. 14). The third dimension of the box, its width (see dimension W in FIG. 14) is the dimension transverse to the axis of box travel and the dimension of the box between the ends on which the flaps will be folded.

Thus, according to these definitions, the length of the paper sheet will wrap two lengths of the box and two heights of the box, whereas the width of the paper will cover a single width of the box plus additional paper adequate to form flaps and folds at the two ends. Typically the longer dimension of the box will be that which is considered its width herein, and the definitions are selected simply as an aid in description and not in a limiting sense. It will be clear, after a complete description of the invention, that a rectangular box can be inserted into the gift wrapping machine in any of a plurality of orientations, whereupon it will be measured and wrapped, with a smooth sheet covering four sides defined herein as the length and height, and end flaps formed on the ends of the box separated by the dimension defined as the width.

The manner in which the measuring apparatus in the station 42 determines the length, width and height of the box will be described below. Suffice it to say for the moment, that those dimensions have been determined and passed to the processor such that the processor can compute the length and width of the sheet to be cut from a selected roll. In making that determination, the length of the sheet is computed by taking twice the length the box plus twice the height of the box, plus adding a small margin, such as 1/2 inch. The width of the sheet is computed as the width of the box plus the height of the box plus a small margin, such as 1/2 inch.

For the purpose of cutting a sheet of the computed size from the roll, drive means are provided for measuring out an appropriate length of paper from the roll and severing the tail when the predetermined amount has been withdrawn. That means operates in cooperation with a pair of slitters which trim the edges of the sheet to produce the appropriate width. The slitters are represented at 70 in FIG. 1, and include a driven anvil roller 77 cooperating with a pair of slitter knife discs 70c, 70d. As the paper passes from the input nip rolls 36 to the input 67 of the paper feed 40, it passes between the slitter discs and the anvil roll, and the edges are slit and removed whereupon they fall into a scrap bin 71. As shown in FIG. 4, the slitters 70 are positioned at either side of the machine, and are adjusted by a motor drive 70a and lead screw 70b. The slitters are symmetrical with respect to the centerline of the machine, and operation of the motor 70a moves the slitters in unison either toward or away from the centerline. Thus, the dimension between the slitters is adjusted to accommodate the computed width of the sheet needed for wrapping the package.

In the illustrated embodiment, the drive for withdrawing the appropriate length of the sheet from the selected supply is associated with the paper feed 40, rather than the infeed stand 60. That allows a single drive to be utilized with all reels of paper in the infeed, and does away with the need for replicating a drive for each of the paper reels. Alternatively, each paper roll can be provided with its own computer controlled drive.

In the illustrated embodiment, a drive motor 73, preferably a stepping motor, operates through a drive belt arrangement 74 (see FIGS. 2 and 3) to drive input rollers 75, 76 which define the input end 67 of the paper feed 40. It will also be seen that the belt drives the anvil roller 77 of the slitter arrangement 70 and also drives an idler gear 78. The idler gear 78 in turn meshes with a gear 79 in the selected nip pair 36, so that the motive force produced by the motor 73 drives the infeed roller 75, 76 at a given speed, and through the movable gear 78 also drives the nip rollers 36 at the same speed, to cause the paper to be withdrawn through the nip 36, past the slitters 70 and into the infeed pair 75, 76 of the paper feed 40.

Digression will now be made to point out that the drive motor 73 is preferably a stepping motor drive supplied with drive pulses by a computerized control. In the preferred practice of the invention, the computerized control, having determined the length of the paper needed, outputs a number to a multiplexed drive, which drives the motor 73 with a calculated number of pulses, the number of pulses having been calculated to produce sufficient rotation of the motor to correspond to the desired length of paper.

It is preferred that substantially all of the drives are of the electronic stepping motor type to provide the precision of control which has been found to be desirable. In some cases, it may be possible to reduce expense by utilizing more conventional and less expensive drive motors along with appropriate limit switches or sensors for positioning drives which have a fewer number of required positions or lower precision requirement. As an example, a turntable is described later in this specification, and the turntable can be operated with only three operative positions, the 0 degree position, the 90.degree. position, and the 270.degree. position. While it is preferred to use a stepper drive for the turntable, it may be possible to reduce expense by substituting an ordinary synchronous or induction motor with appropriate limit switches to control the three operative positions.

Referring now in greater detail to FIGS. 3A and 3B, it will be seen that the gear 78, which is in a vertical plane oriented to mesh with gear 79 of the nip pair, but out of the plane of slitter roller 77, has two positions, controlled by an actuator 80. In the FIG. 3B position of the actuator, a cam flat 81 is against an operating arm 82 of a linkage 83 for the gear 79 and the gears are unmeshed. When it is desired to couple rotational drive from the paper infeed 40 to the selected paper roll, the actuator 80 is energized to transfer it to its alternate position shown in FIG. 3A. In the alternate position, the high point of cam 85 deflects the operating arm 82 to the left, causing the gear 78 to mesh with the gear 79 of the selected infeed rollers 36. Thus, when the motor 73 is energized, the belt drive, in addition to driving the infeed rollers 75, 76 and the slitter roller 77, also drives the gear 79 which in turn drives the nip roll pair 36.

In some cases it may be desirable to dispense with the clutch mechanism for transferred motive power between the paper infeed and the reel stand, and to supply each nip pair with an individual electronically controlled drive. In that case, one of the rollers of each nip pair, such as the lower roller, is driven by a stepping motor, and the clutch mechanism is eliminated altogether. Synchronization between the paper supply and the paper infeed is electronically controlled. In FIG. 3A, a dashed box 79a is shown associated with the lower roller to substitute for gear 79. The box 79a represents a drive motor, replacing the gear 79. Such a drive motor will be associated with the lower roll of each nip pair 36-39 of FIG. 1, in this alternative.

With either drive arrangement, paper is transferred from the nip rolls 36 over the slitter roll 77 into the nip between rollers 75, 76 to be carried upwardly by oppositely rotating belts 90 forming the sheet infeed 40. Prior to initiating driving of the motor 73, the slitter discs were positioned laterally (by operating the drive of FIG. 4) to slit the respective to edges of the paper to a predetermined width. Thus, the paper is driven through the slitters which defines its width and carried into the paper infeed 40. When the electronic control determines that the calculated length of paper has been withdrawn, a knife apparatus generally indicated at 90 is triggered to sever the tail of the paper. The lead edge of the paper is thereupon maintained between the nip rollers 36, while the drive 73 continues to rotate to bring the paper into a "ready" position in the belts 40.

FIG. 3A schematically illustrates elongated paper guides 67 (which span the width of the machine), and are wide at the entrance and narrow at the exit. The guides are adapted to guide the lead edge of the paper from its supporting point between the nip rolls 36, until the lead edge is again supported in the nip 75, 76. The paper is adequate stiff to travel from nip to guide and guide to guide, to be reliably transferred into the belt drive 40. That is particularly true when the paper is being driven both by the nip rollers 36 at the output of the paper storage section, and then drawn into the sheet holder by means of input nips 75, 76 and a plurality of driven belts across the width of the machine.

Referring concurrently to FIGS. 2 and 3, it will be seen that the knife 90 has an elongated cutter bar 91 fixed in a guide 92 which allows the knife to move vertically in the guide. A motor 93 drives a sprocket 94 associated with chain 95 such that rotation of the motor withdraws the knife to a raised position. When it is desired to sever the tail of the paper web, a clutch in the sprocket is released to allow the knife 91 to drop sharply downwardly, severing the tail of the paper, allowing the sheet to progress into the belt 40, and leaving a lead edge between the nips 36 for the next cycle. After the paper is severed, the motor 93 is energized to rotate the sprocket 94, and drive the chain 95 to raise the knife in preparation for the next cycle. However, at that time, there is a sheet of paper contained within the belts 40 which is of length dimensioned to wrap four sides of the box, and of a width dimensional to provide folded flaps on the box ends.

As an alternative to the gravity operated knife 90, a transverse traveling slitter arrangement can be provided. The slitter has a knife which is displaced to contact with paper, whereupon the slitter is quickly traversed across the width of the web to sever the sheet.

It was noted above that a box of arbitrary size was measured as it was input into the machine. Returning to FIG. 1, it will be seen that the box can be positioned by hand on the table in any location between the input pusher 43 and the measuring station 42. It is not important that the box be manually centered, simply that it is placed in approximately the correct orientation, with the ends of the box which are intended to receive the flap oriented at about 90.degree. to the centerline of the machine.

The measuring apparatus 42 has photoelectric measuring means 100 (see FIG. 6) positioned on an extended arm 101 of a carriage 102. The carriage 102 in turn can be driven in a vertical direction by a drive generally indicated at 103. The photoelectric measuring means 100 includes a light source mounted on one arm 101, and a receiver, such a phototransistor, mounted on the opposite arm 101 (see FIG. 7). The phototransistor thus produces a signal one level when the beam falls on the phototransistor, and at another level when the box interrupts the beam. In addition to the photoelectric sensor, associated with the arm 101, there are a pair of centering arms 107 fixed to ball nuts 106 driven by a lead screw 105 operated by motor drive 104. Operation of the motor drive 104 in a first direction moves the centering arms 107 toward the centerline of the machine, and in the other direction away from the centerline of the machine.

With that understood, and referring again to FIG. 6, it will be seen that after a box 99 is manually positioned in the machine, the pusher 43 is driven forwardly into the machine. The mechanism for driving the pusher is a motor drive 110 (FIGS. 1 and 2) which drives a timing belt 112 (see FIG. 7) which in turn rotates lead screws 113 on either side of the machine. The lead screws drive ball nuts 114 which carry the pusher 43. Thus, energizing the motor 110 (FIG. 1) in a given direction drives the pusher 43 into the machine carrying the box with it. At a point determined by the size of the box, the leading edge of the box will break the light beam between the measuring arms 101, signaling the controller that the lead edge has been detected. Since the controller knows the position of the follower 43 by virtue of knowing how many pulses it took to bring the pusher 43 to the position where the light beam was broken, the control circuit can compute the length of the box. The pusher 43 continues to drive the box into the machine toward a "start-wrap" position at which the lead edge of the box is near the slot where the lead edge of the paper (see FIG. 8) is positioned. Either while the box is driving forward, or after the box reaches that position, the vertical drive 103 for the measuring arms 101 is energized to cause the arms to move from their lowermost solid line position of FIG. 6 to a position where the light beam is again detected. That signals the fact that the arms have progressed past the height of the box. Since the controller knows the number of pulses for the drive motor 103 which caused the arms 101 to travel the distance corresponding to the height of the box, the controller calculates the height of the box. Thus, at this point, two of the three box dimensions are known.

After the box 99 reaches the start-wrap position, or just before it reaches that position, the drive 104 is energized to rotate the lead screw 105 and move the centering arms 107 toward the centerline of the machine. The box is carried toward a centered position between the arms 107, and when both arms 107 engage the respective edges of the box as shown in FIG. 7, the arms 107 will pivot about pivot points 121 to close electric switches 122, signaling the controller that the box is centered and in position. Since the controller knows the number of pulses which were coupled to the motor 104 to reach that position, it then calculates the width of the box. At that point, the controller has measured all three dimensions of the box. It is those three dimensions which are used to drive the paper infeed mechanism, and the slitter positioners, to cut a sheet of paper from the paper supply which corresponds to the dimensions of the box of arbitrary size.

FIG. 8 illustrates the lead edge 99a of the box 99 in the start-wrap position. It will be seen that the sheet holding belts 40, and the output nip 41 are positioned adjacent an aperture 130 in the table. An elongate guide 131 guides the lead edge of the paper from the nip 41 through the aperture 130.

Prior to moving the paper into that position, however, adhesive is applied to the leading edge 99a of the box as shown in FIG. 7. FIGS. 6 and 7 show respective views of an adhesive applicator 132. The illustrated embodiment includes a nozzle 133 which has a ball tip closure such that when the nozzle is pressed against the lead edge of the box, a spot of glue is applied to the box. The illustrated adhesive applicator 132 is driven in two dimensions. A first drive arrangement 134a include lead screw 134 moves the nozzle 133 almost into contact with the box. A second horizontal drive 135 operating through lead screws 136 (see FIG. 5) translates a carriage 137 carrying the glue nozzle 132 across the width of the machine. A solenoid connected to the applicator 132 pulses the nozzle forward whenever a spot of glue is to be applied. When the box is in the ready-to-wrap position of FIG. 7, the glue gun is moved along the path shown in FIG. 7 by the horizontal drive 135, while the solenoid periodically forces the tip of the nozzle against the box to cause contact to apply a series of dots of glue across the lead edge of the box.

With the box thus prepared with adhesive, the paper feed rollers 40 are energized to cause the lead edge 98a of the paper sheet 98 to project upwards through the aperture 130 as shown in FIG. 8. A second pusher arm 140 is then translated toward the box, while the pusher arm 43 restrains the box in the rearward direction so that pressure is applied to the paper to cause the adhesive to fix the lead edge 98a of the paper to the lead edge 99a of the box. After the glue is set, the paper drive is again indexed, causing the paper to feed out between the belts 40 while the box 99 is translated further into the machine by concurrent drive of the pushers 43 and 140. A top roller 148 controlled by a drive motor 149 operating leading screw 149a is moved downwardly into contact with the top of the box to restrain the box as the paper is being wrapped thereon. That operation is illustrated in FIG. 9 and it will be seen the ultimately the box 99 reaches a position in which the paper is wrapped across a portion of the lead edge 99a, and across the bottom of the box. At the point, driving of the pushers 140 ceases to stop the box motion. The pusher 43 is withdrawn to allow room for a wiper mechanism to begin wrapping the remaining three sides of the box with the sheet of paper. The sheet drive 40 allows the sheet to continue to be withdrawn from between the belts, while a wiper 150 is driven upwards by means of a drive 151 (FIG. 1) including lead screw 152 positioned below the surface of the table. The wiper mechanism 150 has a leading roller 153 which firmly presses the paper sheet against the trailing edge 99b of the box to achieve a relatively sharp corner at the corner of the box and to wrap the paper upwardly as illustrated in FIG. 10. When the pusher reaches the top of the box, as will be determined by the processor counting pulses for the drive motor, the wiper is stopped in its vertical position and the pusher 140, is reversed to drive the box in the reverse direction as illustrated in FIG. 10. A resilient wiper blade 155 folds the upper corner and presses the paper against the top surface of the box as the pusher 140 translates the box from right to left as shown in FIG. 10. By that point, it will be seen that the trailing edge 98b of the paper is free of the infeed belts 40, and is being carried over the top of the box by the wiper assembly 150.

The pushers continue to translate the box from the position shown in FIG. 10 to the position shown in FIG. 11 at which point the adhesive applicator 132 is again brought into play, as shown in FIG. 11, to apply another pattern of glue dots for securing the trailing edge 98b of the paper. After the glue is applied, as shown in FIG. 12, the wiper 150 is translated downwardly to wrap the paper around the upper right-hand corner of the box, and to smooth the trailing edge 98b into the previously applied glue pattern. FIG. 12 also shows that the box measuring carriage 102 is positioned in contact with the top of the box to hold the box during that operation, the box being firmly supported on the table and held by the pusher 43 and the apparatus 102 while the wiper 155 wipes the trailing edge of the paper into position. At that point, as illustrated in FIG. 14, the box has four sides wrapped, but two ends have projecting flaps.

For completing the wrapping, the apparatus has a further station 47 adapted to fold the flaps and then secure them in position. In the embodiment of FIG. 1, the station 47 includes a turntable and is adapted to fold and fix the flaps on one end of the box at a time. However, it will be apparent that the turntable can be eliminated, and complementary mechanisms provided on each end of the box for folding and fixing both sets of flaps at the same time. The principles will be the same.

FIG. 14 shows that the pusher 140 has moved the box into approximately centered position on a turntable, and FIG. 15 shows the turntable has rotated 90.degree.. In this position, the first set of unfolded flaps is presented to the flap folding mechanism. The turntable 160 has a surface 161 comprised of a drivable belt which can position the box with respect to the turntable along the axis of the machine (in the FIG. 15 direction). However, before driving the belt 161 for repositioning the box, the box must be centered with respect to the machine centerline, to insure the flap folding mechanism engages the box appropriately. To that end, a centering mechanism (FIG. 16) is provided comprising a set of pushers 270, 271 driven by a motor drive 272 operating through a set of lead screws 273, and adapted to move the pushers 270, 271 toward or away from the centerline of the machine. Thus, the motor drive 272 is engaged to drive the pushers 270, 271 inwardly, to move the box to a centered position on the belt, when both pushers feel resistance, the mechanism senses that the box is centered, and the pushers are withdrawn. The box is then centered on the drive belt, with a first open end 99b of the box facing outwardly for access by flap folding apparatus 163. For securely restraining the box during the folding and fixing operation, an upper restraining drive 164 is lowered by means of a drive motor 164a driving four lead screws 165 positioned at the corners of the upper apparatus. In the illustrated embodiment, the upper carriage 163 also has a driven belt 166.

In summary, the pusher 140 as shown in FIG. 14 pushes the partly wrapped box onto the conveyor belt of turntable 160. The turntable then rotates about its center to the position shown in FIG. 15, the box is recentered and thereupon the upper restraining carriage moves downwardly to move the belt 164 into engagement with the top of the box as shown in FIG. 16. A drive 170 for the lower belt and a similar drive 170a for the upper belt are thereupon energized to move the edge 99b of the box forward to near the edge of the turntable.

Referring to FIG. 17, it will be seen that the folding mechanism includes a set of four resilient fingers 171-174, which are positioned by the controller at the corners of the face 99b of the box to fold the first two flaps. A vertical drive 175 operating through lead screws 176, 177 moves the upper fingers 172, 173 upward with respect to the bottom set of fixed fingers 171, 174. The controller moves the fingers in dependence on the height of box measurement previously obtained. A horizontal drive 180 operating through lead screw 181, 182 thereupon moves the fingers inwardly toward the centerline of the machine to a dimension determined by the previously measured length of the box. When the fingers are positioned in the orientation shown in FIG. 18, the belt drives for the upper and lower belts are then energized to move the box forward so that the flap portions 98c, 98d engage the fingers 171-174 and are carefully and neatly folded inwardly as shown in FIG. 18. The paper is carefully folded over the vertical edges of the box as shown in FIG. 18. Switch mechanisms associated with the resilient arms 171-174 signal the controller to stop the drive when the box drives forward sufficiently to flex the fingers thereupon indicating that adequate folds of the short flaps have been made.

Having made the first set of folds to create the short flaps, a lower flap folder 186 (FIGS. 17 and 20) is pivoted outwardly so that a channel member 187 engages the lower corner of the box, forming a fold in a lower long flap 98e, and holding it against the end of the box. The lower fingers 171, 174 are thereupon trapped in the flap, but as they are of thin resilient material, that is of no effect. After the bottom flap 98e is folded, a second adhesive applicator 185 (FIGS. 17 and 19) is brought into play to apply adhesive to the outside of the lower flap 98e. Following the application of the adhesive, an upper wiper assembly 190 is driven downwardly, causing a resilient blade 191 positioned along the edge of the wiper to fold the final long flap 98f downwardly, ultimately causing the trailing edge of the flap 98f to come into contact with the previously applied adhesive. In one embodiment of the invention, the wiper assembly 190 is caused to dwell for a short time to allow the adhesive to set up. At that point the horizontal drive for the fingers is energized to move the fingers away from the centerline of the machine, thus withdrawing them from the flaps.

Following the folding and fixing of the flaps on one end of the box, the upper and lower belts are driven in the reverse direction, so that the box is returned to the centered position, generally as it had been illustrated in FIG. 15. The upper belt is raised, and the turntable 160 rotated 180.degree. to bring the unfolded edge 98f of the box forward for processing as has been described in connection with the previous flap. After that set of flaps is folded and fixed, the upper belt is retracted, the lower turntable rotated 90.degree., and the fully wrapped package delivered from the machine as illustrated in FIG. 22.

Certain aspects of the flap folding and fixing operation will be emphasized. The measurement of the width of the box allows the processor to determine a width for the paper sheet 98 to allow a predetermined dimension D (FIG. 18) by which the flaps extend beyond the edge of the box. Controlling that dimension allows the flaps to present a neat and attractive appearance. Thus, the fingers 171-174 when they engage the flaps in their unfolded condition, extend sufficiently far into the box to fold the flaps downwardly and smoothly to form a substantially square flap section 98g, 98h at the ends of the box. That provides for substantially uniform 45.degree. angle creases on the flaps 98e, 98f when they are rolled into position.

In the embodiment of the invention described thus far, the adhesive applicator has employed a cold set pressure-applied glue. An exemplary gluing system for that embodiment is illustrated in FIG. 13. There is shown a glue nozzle 130 and a solenoid 200 adapted to drive the nozzle forward and backward in order to contact the box for depositing spots of glue. It will be seen that glue is supplied to the nozzle byway of a hose 201 connected to a double sealed cylinder 202. The cylinder, which has an upper sealing gasket 204 has its upper chamber 205 filled with cold set glue. A refill plug 206 allows additional glue to be put into the chamber for refilling. A second lower piston chamber 210 is provided having its own separate sealing mechanism 211. The lower chamber is supplied with pressurizing gas, in the exemplary embodiment from a compressed carbon dioxide source 207 operating through a regulator 208. Thus, a continuous relatively low pressure is maintained on the glue so that when the nozzle 130 contacts the box to displace a ball in the nose of the nozzle, there is a known pressure applied to the glue at the nozzle to apply a given amount of glue during the time the ball is displaced. A piston 215 which separates the two chambers 205, 210 is guided on a piston rod 216 which has a ring 217 positioned thereon. The position of the ring 217 is sensed by a low glue sensor 218 when the chamber 205 is substantially empty, producing a signal which prevents the controller from wrapping further boxes until the glue chamber is again refilled.

It is also possible to use a hot melt glue with a modified nozzle. In that application, the hot melt glue is applied in solid form to the nozzle, and is melted in the nozzle before application to the package.

While the cold set adhesive system provides certain advantages, particularly in economy, it does at least in some embodiments increase the cycle time. Not only does it take time to traverse the glue gun across the box and deposit drops of glue, but more significantly, many cold set glue products require a finite number of seconds to set up. The wiper must remain in contact with the box for that number of seconds to allow adhesive set up.

In the presently preferred form of the invention, a different form of adhesive applicator is used. As illustrated in FIG. 23, the adhesive applicator comprises a strip of adhesive supplied in tape form and applied to the box or the flap by simply wiping the tape along the box. The tape is commonly known as an adhesive transfer tape, and is available, for example, from the 3M Company.

FIG. 23 illustrates a mechanism for applying the tape. A supply reel 250 is provided containing a commercial available reel of the transfer adhesive on its standard backing paper. An end 251 of the paper backed adhesive is unwound from the reel 250 and wrapped around an applicator roller 252. Contact of the outside of the tape 251 with the box surface (assuming a supply brake 256 is released) allows the adhesive to be applied to the surface along which it is wiped, while the now bare backing tape 253 is wound around a take-up reel 255. A solenoid 256 is provided for controlling the rotation of the supply reel 250. When the solenoid is de-energized as shown in FIG. 23, the reel 250 is locked, so that the dispenser will not apply adhesive to a surface along which it is wiped. However, when the solenoid 256 is energized, the brake is released, and if the roller 252 is wiped along a surface by relative movement between the apparatus 249 and the surface as illustrated by the arrow, a thin strip of adhesive will be applied to the box.

Thus, to apply the adhesive dispenser of FIG. 23 to the apparatus of FIG. 1 simply requires a position mechanism to bring the adhesive applicator into appropriate orientation with respect to the box, to drive it forward so that the roller 252 is in contact with the box, then to translate it along the surface of the box so that a strip of adhesive will be applied. In order to accomplish that in the apparatus of FIG. 1, a traversing mechanism such as is shown in FIG. 24 will be used. There is shown the tape applicator 249 and its applicator roll 252 mounted in the upper portion of a carriage 260. The carriage 260 in turn is carried on a linear bearing 261 and is adapted for translation fore and aft (toward or away from the box) by means of a drive motor 262 operating a ball screw 263 fixed in a ball nut 264 which carries the carriage 260. Thus, the motor 262 brings the applicator roller 252 into contact with the box. A second horizontal drive 265 then rotates a lead screw concentric with the drive for translating the entire carriage and vertical drive mechanism along a linear bearing 267. Thus, the drives 262, 265 are operated to bring the applicator roller 252 into contact with the box at one edge, then the drive 265 is engaged to wipe the roller 262 along that edge (while the solenoid is energized) to apply a thin strip of adhesive to that edge. An applicator such as that schematically illustrated in FIGS. 23 and 24 will be positioned in two locations in the machine of FIG. 1. One will replace the glue applicator which applies the first glue pattern to the lead edge of the box. Indeed, with respect to that glue applicator, it will be necessary to operate it only once, to apply a thin strip of tape, which will be only half covered by the lead edge of the paper (FIG. 8), leaving half the adhesive strip available for securing the trailing edge (FIG. 12) without the need for a second adhesive application in wrapping the first four sides of the box. A second adhesive applicator will replace the gluing station 48 (FIG. 1), and will apply a strip of adhesive either across the first flap, or between the flaps, to secure the flaps in the flap fixing operation. Indeed, in the second wrapping station, a pair of adhesive applicators can be provided in order to allow flaps on both sides to be folded and secured simultaneously, and to eliminate the need for a turntable.

The machine described in connection with the previous embodiments has included primarily two operating stations and a paper supply station. A first operating station measured the box as it was input and then, after measurement, applied the paper to overwrap four sides of the box. The box was thereupon transferred to a second station where the flaps were folded and fixed on the box edges. In a machine of that construction, two boxes can be wrapped simultaneously, even with different types of papers, and even of different sizes. Measurement of the first box and wrapping of four sides of the first box is accomplished whereupon the first box is passed to the second station for folding and fixing flaps. During the time the flaps are being folded and fixed, a new paper supply and a new box commence the first portion of the operation.

In an even more preferred configuration of the invention, it is contemplated that a three-station machine will be provided. A first station will utilize the measuring apparatus of FIG. 1 in a separate station to measure the box and begin to measure the sheet. A second station will wrap the first four sides of a second box. A third station will fold and fix flaps on the box edges. All three stations can run concurrently on different boxes, thus increasing throughput.

FIG. 25 illustrates the primary elements of a process controller capable of operating the machine of FIG. 1 as described in detail above. The controller is based on a conventional microprocessor 200. Internal to the computer 200 is a standard memory 202 which can consist of a combination of random access memory, ROM and/or disk memory which contains the program necessary to achieve the functionality described herein. The conventional microprocessor can include a keyboard 203 and a display 204 such as a CRT display. Those elements may be useful in reconfiguring the system, although they are typically not needed during normal operation of the gift wrapping machine.

One of the significant programs to be operated by the microprocessor 200 in conjunction with its memory 202 is a timer module which is separately identified in the drawing as module 210. The module 210 is separately identified because in the preferred practice of the invention, the timer module 210 produces pulses which are output through a driver to drive a conventional stepping motor. Alternatively, in the case where synchronous motors or synchronous stepper motors are used, the timer module 210 simply controls the amount of time during which the drives are operated, thereby controlling the indexing.

The microprocessor 200 interfaces to the package wrapping machine 30 through an I/O interface 212. The I/O interface is a conventional circuit which takes output signals generated by the processor and passes them to the appropriate devices on the package wrapping machine, and appropriately interfaces input signals, such as interrupts or the like from the machine to the processor. One of the more significant outputs produced by the processor for driving the package wrapping machine 30 is drive signals to the numerous drive motors. In the preferred practice, a drive multiplexer 214 is utilized so that drive electronics shown at 215 can be utilized for driving more than a single motor. As an alternative, each motor can be supplied with its own power driver, and can accept signals from the microprocessor demanding a certain number of pulses or amount of rotation. However, as the system is currently configured, the drivers 215 are multiplexed at 214 to drive the motors identified by box 216. The package wrapping machine also includes a box identified as input switches 217. That module includes switches from the centering mechanism, the photoelectric sensors and the like. Also, any operator input switches, such as stop switches, start switches, etc. would be represented by the input switch module 217. The signals generated by those switches are passed to the I/O interface 212 which is periodically scanned by the microprocessor to cause the system to respond to the sensed conditions.

FIGS. 26A-26B and 27A-27B represent a program of operation by which the processor system of FIG. 25 operates to control the package wrapping machine of FIG. 1. FIGS. 26A-26B and 27A-27B are positioned side by side in that the blocks in FIGS. 26A-26B relate to the blocks in FIGS. 27A-27B. The blocks in FIG. 26A-26B are described in terms of their functionality in connection with wrapping a package, whereas the corresponding blocks in FIGS. 27A-27B are described in connection with their functionality of driving the mechanical elements of the package wrapping machine. The diagrams of FIGS. 26A-26B and 27A-27B will thus best be reviewed together. For the sake of illustrating the relationship, the blocks of FIGS. 26A-26B will be given reference numerals and the blocks of FIGS. 27A-27B will be given the same reference numerals primed. In most cases, only the unprimed reference numeral will be referred to, but attention will typically be focused on both related blocks.

The process starts at 250, at which point the operator has selected the type of paper, inserted the box in the appropriate position in the machine, and accomplished whatever other additional preliminary steps are need. Upon actuating the start switch, the processor first performs a step 251 to select a paper supply from one of the four paper supplies. Functionally, that is accomplished by indexing the paper carriage.

The process then progresses to the step 252 of indexing and measuring the box. In the apparatus of FIG. 1, the drive carriage is energized, which causes the box to be advanced into the machine, while the processor continues to sense for the presence or absence of the light beam. The fact of the beam being broken is first sensed to determine the length of the box, and then as the carriage is raised, the fact of the beam reappearing is again sensed to determine the height of the box. Following the step 252, step 253 is performed to compute the size of the paper sheet need to wrap the box which had been measured in step 252. For the length of the sheet, all that needs to be done is to calculate two times the length plus two times the height and add a small overlap, such as 1/2 inch. For the width, it is necessary to calculate the width of the box and add the height plus a small margin such as 1/2 inch.

Having determined those dimensions, they are translated to pulse drive counts, and step 254 is performed to cut and slit the paper sheet. As a first part of that operation, the step 254' adjusts the slitter width to produce the width of the sheet desired. The paper drive is then engaged to begin to draw the paper from the supply roll. Concurrently the gear which couples the paper drive to the paper supply is engaged. The paper is withdrawn and slit until the determined number of pulses is counted which is related to the calculated length of the sheet, following which the knife is actuated to sever the sheet.

A step 255 is then performed to apply adhesive to the leading edge of the package. Functionally the adhesive applicator is indexed by the appropriate drive to bring it into contact with the box and then indexed across the box to apply a strip of adhesive or a line of adhesive dots. A step 256 then applies the leading edge of the paper to the adhesive treated portion of the box. Functionally that is accomplished by indexing the paper drive to advance the paper edge above the plane of the table, and to index the second follower to press the paper against the adhesive. A step 257 is then performed to wrap four sides of the box. Functionally that is accomplished by indexing the box pusher until the bottom the box is wrapped, then terminating the indexing. The wiper is then indexed in an upward direction to wrap the first vertical side of the box, and when the wiper reaches the top of the box, indexing is terminated. The box drive is then indexed in the reverse direction to reverse the box until the third side, the top of the box, is wrapped. Box indexing stops at that point and the wiper is again indexed to return it to the lower position. In the case of the cold set applicator, glue is applied before the performance of the last portion of that operation. If the strip adhesive is utilized with part of the adhesive projecting, the second gluing step can be eliminated.

A step 258 then indexes the box to the next station. Functionally, that is accomplished by engaging the pusher to index the box onto the turntable. A step 259 then adjusts the fingers and folds the first flap. That is accomplished by indexing the finger drive to separate the fingers by about the height of the box. Following that the box drive is advanced to cause the box with extended flaps to engage and be driven into the fingers until a flap is formed and the fingers press the flap against the edge of the box.

A step 260 is then performed to fold the second flap. Functionally in the exemplary embodiment that is performed by raising the flap wiper to hold the lowermost flap in position. Adhesive is then applied in a step 261 which functionally is accomplished by positioning the adhesive applicator in the appropriate spot on the box (as determined by the computed dimensions), and indexing the drive along the length of the box to which adhesive is to be applied.

A step 262 is then performed to fold the last flap. Functionally, that is accomplished by indexing the upper wiper down past the portion of the paper which is underlied by adhesive, and if necessary, holding it in position for a sufficient dwell time to allow the adhesive to set up. A step 263 releases the box by withdrawing the fingers from the folded flaps and raising the holddown carriage. A step 264 then ejects the wrapped box from the machine, which is functionally accomplished by indexing the eject drive.

It will now be appreciated that what has been provided is an automatic package wrapping machine which is fully functional to provide a neatly wrapped package for boxes of arbitrary size. In the preferred embodiment, gift wrap paper is selected from a plurality of supply rolls. The box which is simply placed in the machine is measured as it is indexed into position to determine the three dimensions which define the rectangular box. The processor computes the size of the sheet needed to wrap a box of the measured size, and a paper drive actuated to withdraw sufficient paper and cut from the withdrawn supply a sheet of paper of the determined size.

Adhesive is then applied to the box, the lead edge of the paper is applied to the adhesive, and four sides of the box are automatically overwrapped, all while maintaining precise and positive control over the position of the box, and without tipping or inverting the box.

Following the overwrapping of four sides, the box is preferably indexed to another station where automatic flap folders, preferably in the form of resilient fingers, engage the flaps to make a first fold in the flaps. A glue applicator and further wipers then crease and fold the remaining two folds. When that is accomplished on both sides, a completely gift wrapped box is produced, without the need for human intervention between inserting the box in the machine in the first instance and picking it up after it is ejected fully wrapped.