BODY PANEL WRAPPING METHOD AND APPARATUS

Abstract

A body panel wrapping apparatus is provided, the body panel wrapping apparatus having a frame; a roll receptable associated with the frame and pivotally engaged with a wrapping roll; and a panel engaging portion associated with the frame, wherein the panel engaging portion is configured to be selectively engaged with a panel and selectively rotated about a rotational axis, wherein rotation of the panel engaging portion about the rotational axis is configured to wrap the panel in wrapping from the wrapping roll. The roll receptacle may be configured to selectively increase the force required to rotate the wrapping roll, creating tension to tightly wrap the panel while rotating. The body panel wrapping apparatus may have a rotation controller and foot pedal configured to allow a user to wrap a body panel without a second user. The wrapped panel may fit in a smaller package, reducing shipping costs.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/384,850, filed on Nov. 23, 2022, which is hereby incorporated by reference, to the extent that it is not conflicting with the present application.

BACKGROUND OF INVENTION

1. Field of the Invention

The invention relates generally to methods and apparatuses for wrapping panels and specifically to methods and apparatuses for automatically rolling and wrapping body panels.

2. Description of the Related Art

In the automotive industry, automotive manufactures are often reliant upon imported parts and components in order to acquire the necessary elements to fully assemble their products. Structures such as body panels, including bumpers, may be manufactured offsite and imported in order to save on manufacturing costs or utilize body panels from a preferred manufacturer during vehicle fabrication. However, after being manufactured, completed vehicle body panels may be large and cumbersome, thus having larger dimensions that require large boxes or packages in order to ship to their destination. Larger packages often cost more to ship, thus resulting in hefty shipping costs for transporting completed vehicle body panels, particularly when shipping them internationally. In some instances, the shipping costs associated with shipping a body panel internationally may exceed the price of the body panel itself, adding significant expenditures to the vehicle manufacturing process.

Therefore, there is a need to solve the problems described above by proving a device and method for efficiently wrapping a body panel to reduce its overall dimensions to minimize packaging volume.

The aspects or the problems and the associated solutions presented in this section could be or could have been pursued; they are not necessarily approaches that have been previously conceived or pursued. Therefore, unless otherwise indicated, it should not be assumed that any of the approaches presented in this section qualify as prior art merely by virtue of their presence in this section of the application.

BRIEF INVENTION SUMMARY

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description.

In an aspect, a body panel wrapping apparatus is provided, the body panel wrapping apparatus being configured to quickly and automatically wrap a body panel for a vehicle, structure, etc. with minimal or no human interventions. Thus, an advantage is that panels may be wrapped more quickly, efficiently, and with reduced labor costs. Another advantage is the reduced likelihood of body panel damage, as a result of the high level of reproducibility enabled by using an automated device to perform this operation. Another advantage is that the automatic nature of the panel wrapping apparatus allows for wrapping operations to be scaled more easily.

In another aspect, a body panel wrapping apparatus is provided, the body panel wrapping apparatus having a panel engaging portion configured to engage with a panel and rotate, rolling the panel into a compact package while simultaneously covering said panel with a layer(s) of wrapping. In said aspect, the panel engaging portion may have a moving compression arm and a stationary compression arm, wherein the body panel is configured to be selectively compressing between the moving and stationary compression arms. Thus an advantage is that the overall size of the panel may be reduced, thus allowing for a smaller box or package to be used to package the panel, thus reducing the packaging cost. Another advantage is that the resultant smaller package will also be cheaper to ship, especially internationally, wherein the cost of international shipping contributes greatly to the overhead costs of outfitting a vehicle with panels. Another advantage is that the wrapping may protect not only the outer surface of the wrapped panel, but also the internal surfaces of the wrapped panel that said wrapping is layered between as the panel is rolled, thus reducing the chances of the panel scratching itself as it is rolled or shipped. Another advantage is that if wrapped body panels need to be stored in inventory prior to shipping, the amount of inventory space required may be reduced when compared to storing unwrapped body panels.

In another aspect, a body panel wrapping apparatus is provided, the body panel wrapping apparatus being configured to be controlled by a programable logic controller, such that the operation of the body panel wrapping apparatus may include automated procedures. Thus, an advantage is that the usage of automation may improve productivity and minimize apparatus down time, and with limited human intervention. Another advantage is that the labor required to wrap body panels may be reduced, thus increasing profitability.

In another aspect, a body panel wrapping apparatus is provided, the body panel wrapping apparatus have a plurality of control elements, such as rotation controllers and control pedals configured to facilitate operation of its various electrical and pneumatic elements of the body panel wrapping apparatus. Thus an advantage is that the performance of the various necessary operations, such as rotation of the panel engaging portion and movement of the moving compression arm toward and away from the stationary compression arm may be done by a user my simply pressing a button, depressing a pedal, etc., thus making it easier for a singular user to wrap a panel without outside assistance. Each control element may be configured to electrically and/or pneumatically control a corresponding element of the body panel wrapping apparatus, utilizing a pressure and/or electricity source to facilitate fast and easy wrapping of each body panel.

In another aspect, the body panel wrapping apparatus may further comprise a roll receptacle configured to pivotally engage with and selectively compress/restrict rotation of a wrapping roll. Thus an advantage is that the roll receptacle's engagement with the wrapping roll may apply tension on the wrapping from the wrapping roll as it is applied to the body panel, thus creating a tight wrapping layer around the body panel, protecting it from damage and minimizing its size. The type of wrapping on the wrapping roll may be varied in accordance with the needs of the application, required material strength, etc.

The above aspects or examples and advantages, as well as other aspects or examples and advantages, will become apparent from the ensuing description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For exemplification purposes, and not for limitation purposes, aspects, embodiments or examples of the invention are illustrated in the figures of the accompanying drawings, in which:

FIGS. 1A-1C illustrate the front, right and left side perspective views, accordingly, of a body panel wrapping apparatus, according to an aspect.

FIG. 2A illustrates the front view of the panel engaging portion of the body panel wrapping apparatus, according to an aspect.

FIG. 2B illustrates the front-left side perspective view of the panel engaging portion of the body panel wrapping apparatus, according to an aspect.

FIG. 2C illustrates the left side perspective view of the panel engaging portion of the body panel wrapping apparatus, according to an aspect.

FIG. 2D illustrates the top right perspective view of the panel engaging portion of the body panel wrapping apparatus, according to an aspect.

FIG. 3 illustrates the front perspective view of the air cylinder and roll top keeper, according to an aspect

FIG. 4A illustrates the front view of the rotation controller and control motor of the body panel wrapping apparatus, according to an aspect.

FIG. 4B illustrates a side perspective view of the control panel, according to an aspect.

FIG. 4C illustrates a front perspective view of the control without a front cover, according to an aspect.

FIG. 5 illustrates the front perspective view of a bumper being pre-heated in a panel oven, according to an aspect.

FIG. 6 illustrates a front perspective view of a user inserting an end portion of the bumper between the compression arms of the panel engaging portion of the body panel wrapping apparatus, according to an aspect.

FIG. 7 illustrates a front perspective view of the panel engaging portion being rotated to continually roll and wrap the bumper, according to an aspect.

FIG. 8 illustrates a front perspective view of the rolled bumper being continually rotated to provide additional layers of wrapping around the bumper, according to an aspect.

FIG. 9 illustrates a front perspective view of the compression arms, being partially disengaged from the wrapped bumper, according to an aspect.

FIG. 10 illustrates the top perspective view of a wrapped bumper placed within a box for shipping, according to an aspect.

FIGS. 11A-11D illustrate embodiments of the program files utilized by the programmable logic controller of the body panel wrapping apparatus, according to an aspect.

DETAILED DESCRIPTION

What follows is a description of various aspects, embodiments and/or examples in which the invention may be practiced. Reference will be made to the attached drawings, and the information included in the drawings is part of this detailed description. The aspects, embodiments and/or examples described herein are presented for exemplification purposes, and not for limitation purposes. It should be understood that structural and/or logical modifications could be made by someone of ordinary skills in the art without departing from the scope of the invention.

It should be understood that, for clarity of the drawings and of the specification, some or all details about some structural components or steps that are known in the art are not shown or described if they are not necessary for the invention to be understood by one of ordinary skills in the art.

“Logic” as used herein and throughout this disclosure, refers to any information having the form of instruction signals and/or data that may be applied to direct the operation of a processor. Logic may be formed from signals stored in a device memory. Software is one example of such logic. Logic may also be comprised by digital and/or analog hardware circuits, for example, hardware circuits comprising logical AND, OR, XOR, NAND, NOR, and other logical operations. Logic may be formed from combinations of software and hardware. On a network, logic may be programmed on a server, or a complex of servers. A particular logic unit is not limited to a single logical location on the network.

It should be understood that, for clarity of the drawings and of the specification, some or all details about some structural components or steps that are known in the art are not shown or described if they are not necessary for the invention to be understood by one of ordinary skills in the art.

For the following description, it can be assumed that most correspondingly labeled elements across the figures (e.g., 102 and 202, etc.) possess the same characteristics and are subject to the same structure and function. If there is a difference between correspondingly labeled elements that is not pointed out, and this difference results in a non-corresponding structure or function of an element for a particular embodiment, example or aspect, then the conflicting description given for that particular embodiment, example or aspect shall govern.

FIGS. 1A-1C illustrate the front, right and left side perspective views, accordingly, of a body panel wrapping apparatus 101, according to an aspect. The herein disclosed body panel wrapping apparatus (“panel wrapping apparatus,” “wrapping apparatus”) 101 may be used to quickly and easily wrap a body panel (“panel”), or other suitable structure, while minimizing its packaging volume. The body panel wrapping apparatus 101 may be configured to minimize the packaging volume of a body panel, such as bumper 220 of FIG. 2B, by rolling the body panel into a compact shape as it wraps it for shipping and/or storage. Body panels may be preheated prior to rolling and wrapping to prevent damage to the body panel, increase body panel flexibility and reduce the amount of force required to suitably roll said body panel, as described in FIG. 5 hereinbelow. The compact size of the resultant wrapped body panel may allow it to be placed into a smaller, less cumbersome box, thus reducing the costs associated with transporting it. In an embodiment, the body panel wrapping apparatus 101 may be configured to wrap a body panel nearly automatically/autonomously and with minimal human intervention after engagement of the panel with the body panel wrapping apparatus 101, as will be described in greater detail hereinbelow.

The body panel wrapping apparatus 101 may comprise several main components. These main components may include a panel engaging portion 102 configured to engage with and rotate the body panel to enable rolling and wrapping of said body panel. In an embodiment, additional main components may include a rotation controller 105, a control motor 106, a pressure regulator 126, a variable pressure solenoid valve 107 in pneumatic communication with the pressure regulator, 126 and a control panel 108. In an embodiment, the body panel wrapping apparatus 101 may further comprise an optional loading table 104 configured to support a body panel prior to engagement with the panel engaging portion. It should be understood that each main component may be secured to or otherwise associated with a body frame (“frame”) 109 to ensure suitable interconnection of each component as disclosed herein. Each of these components may be further interconnected through corresponding applicable structures, such as wires, hoses, etc. to enable proper apparatus function as described herein.

The body panel wrapping apparatus 101 may have a panel engaging portion 102 that is configured to selectively engage with and subsequently rotate a panel, to allow the panel to be rolled and wrapped using a wrapping roll (“shrink wrap roll”) 103 pivotally engaged with the body frame 109. The rotation of said panel and attachment of a loose end of the wrapping roll 103 to said panel will result in the wrapping roll 103 rotating as the panel rotates. The panel engaging portion 102 may be pivotally engaged with, or otherwise associated with the body frame 109 by virtue of its attachment to a vertical shaft 110 (and its associated connections), and may be disposed above the optional loading table 104. In an embodiment, a body panel may be temporarily supported by the loading table 104 while being engaged with the panel engaging portion 102 by a user. It should be understood that the loading table 104 associated with the body frame 109 may not be included in all embodiments. The panel engaging portion 102 may have a pair of compression arms 102a, 102b configured to behave as a clamp feature, wherein a moving compression arm 102a is associated with the platform 102c and configured to be moved to selectively sandwich/compress a bumper or other body panel between the moving compression arm 102a and a stationary compression arm 102b. This effectively secures the panel between the compression arms 102a, 102b and allows the panel to be securely rolled into a compact package during wrapping, thus making the panel less cumbersome to handle and cheaper to ship.

In an embodiment, the moving compression arm 102a may be moved by an attached compression cylinder, such as compression cylinder 213 of FIG. 2D, as will be discussed in greater detail hereinbelow. In an embodiment, the panel engaging portion 102 may be surrounded by perimeter straps, such as perimeter straps 214 of FIG. 2A, that are configured to ensure that parts of the panel do not protrude beyond the perimeter of the panel engaging portion 102 as it is being wrapped. These perimeter straps may be secured to support posts, such as support post 109a, as will be discussed in greater detail hereinbelow.

In an embodiment, the body panel wrapping apparatus 101 may further comprise an optional loading table 104 that is configured to support a body panel, such as a bumper, before and/or during the wrapping process. This loading table 104 may be slidably associated with the body frame 109 and disposed below the panel engaging portion 102 to provide suitable support for panels that are being engaged with the body panel wrapping apparatus 101 to be wrapped. The loading table 104 may comprise a loading base 104a and a loading wall 104b disposed above and perpendicular to the loading base 104a. In an embodiment, the loading base 104a may be used to support the weight of a panel prior to wrapping of said body panel. The loading wall 104b may be configured to prevent the body panel from being swung around during the wrapping process, by restricting the movement of any unwrapped portion of the body panel, as will be described in greater detail hereinbelow. The loading base 104a or the entirety of the loading table 104 may be configured to slide horizontally, such that it may leave the underside of the panel engaging portion 102 open to the body frame surface disposed below, thus providing additional vertical clearance below a wrapped body panel and providing a user more space to grab said wrapped body panel after wrapping is completed.

In an embodiment, as can be seen in FIG. 1C, the loading base 104a and loading wall 104b may be slidably engaged with the body frame 109 by a pneumatic rail 104c. The retraction of the loading table 104 through the utilization of said pneumatic rail 104c may happen automatically at the end of the timed wrapping cycle, based upon how the programmable logic controller (“PLC”), such as PLC 429 of FIG. 4C, is configured. Overall, the timer function that dictates the timing of automated body panel wrapping apparatus 101 operations may be controlled by a Human Machine Interface screen (“HMI screen”) 150 used in conjunction with the programable logic controller, wherein the PLC and HMI screen are in electrical communication with each other. The extension of the loading table 104 such that it is directly below the panel engaging portion 102 may be triggered by a user pressing foot pedal 111a before or after a completed wrap cycle.

In an embodiment, the rotation controller 105 may be a suitable electronic/electrical device that is configured to be in communication with the panel engaging portion 102 (or more specifically in electrical communication with the control motor 106 that manipulates it) in order to facilitate rotation of the panel engaging portion 102 using the control motor 106. This rotation controller 105 may be configured to rotate the panel engaging portion 102, and thus the compression 102a, 102b arms together, to facilitate wrapping of a body panel. The rotation controller 105 may be provided with a variety of buttons/dials to allow a user to initiate automated wrapping procedures, and/or allow the user to assume manual control of compression arm rotation, thus allowing the user to start and stop the rotation of the compression arms at will. The rotation controller 105 may be configured to facilitate the wrapping of a body panel through coordination with the aforementioned control motor 106 while the body panel is held. As such, the rotation controller 105 and may be in electrical communication with both the panel engaging portion 102 and the control motor 106. While the body panel wrapping apparatus embodiment of FIG. 1A-1C may utilize a control motor 106 to rotate the panel engaging portion, alternative mechanisms, such as a manual crank mechanism (not shown) may instead be used, as will be described in greater detail hereinbelow.

In an embodiment, the control motor 106 may be associated with the frame 109 and configured to facilitate the rotation of a body panel engaged with the panel engaging portion 102 to facilitate wrapping of said body panel. The control motor 106 may be an A/C inverter duty motor, wherein said motor is configured to couple with a gearbox 128. The rotation speed of the control motor 106 may be configured to be controlled by a variable power frequency inverter drive, such as variable power frequency inverter drive 435 of FIG. 4C. This control motor 106 may be configured with the proper specifications (e.g., torque) to allow for the rolling of a body panel in a controlled fashion to prevent damage to the body panel during wrapping. As disclosed herein, the body panels may also be preheated in order to increase their flexibility prior to rolling/wrapping, thus reducing the overall torque required to successfully roll and wrap the body panel. As with any conventional motor, said control motor 106 may be in electrical communication with a power source, such as an electrical outlet, at least indirectly. The control motor 106 may be attached to the body frame 109 and disposed above the panel engaging portion 102, such that a vertical drive shaft 110 disposed between and engaged with the control motor 106 and the panel engaging portion 102 may be configured to spin the panel engaging portion 102 to facilitate wrapping/rolling of an engaged body panel. The interaction between the control motor 106 and the panel engaging portion 102 will be discussed in greater detail hereinbelow.

In an embodiment, the control motor 106 may be an A/C Inverter Duty 5 Hp motor. In said embodiment, the gear box 128 may be a gear box/speed reducer/transmission having a right-angle output with 20:1 reduction ratio. In order to facilitate proper operation of the panel engaging portion 102, the control motor 106 may be directly coupled to the gear box 128. A chain sprocket (not shown) may be mounted to the output shaft of the gearbox 128. A roller chain (not shown) may be configured to connect the chain sprocket to a secondary sprocket (not shown), wherein the secondary sprocket is mounted to the vertical shaft 110. The vertical shaft 110 may pass through an upper mounted bearing (not shown) and lower mounted bearing (not shown) such that vertical shaft 110 engages with the panel engaging portion 102, or more specifically, the platform of the panel engaging portion, such as platform 202c of FIG. 2D. As such, the platform, and thus by extension, the panel engaging portion 102 may be pivotally engaged with the body frame 109. The electrical power provided to the motor for operation may be regulated via a variable power frequency inverter drive, such as variable frequency drive 435 of FIG. 4C, such that the rotation speed of said control motor 106 is controlled by variable power frequency inverter drive.

In an embodiment, the variable pressure solenoid valve 107 may be configured to control the amount of pressure that is applied to the shrink wrap roll 103 to restrict the shrink wrap roll's ability to rotate freely. The resultant pressure exerted on the shrink wrap roll 103 is configured to increase the force required to rotate the wrapping roll (e.g. increase the wrapping roll's resistance to being rotated) to create tension, which helps snuggly wrap the body panel in wrapping from the shrink wrap roll 103 as it is rotated. The tension exerted on the shrink wrap roll 103 may be applied by an air cylinder, such as air cylinder 336 of FIG. 3, in pneumatic communication with the variable pressure solenoid valve 107. The variable pressure solenoid valve may vary the air pressure provided to the air cylinder to achieve the desired pressure/tension to optimally wrap a corresponding body panel. In an embodiment, this air cylinder selectively adjusts (e.g., pulls down) a roll top keeper, such as roll top keeper 337 of FIG. 3, onto the shrink wrap roll 103 to restrict the movement/rotation of the shrink wrap roll 103. The amount of pressure and the time interval over which this pressure is applied may be varied at different stages of the wrapping process and may be controlled by the aforementioned PLC, and/or changed by the user/operator as required via the HMI screen.

In an embodiment, the control panel 108 may act as an electrical hub for all of the electrically powered components of the body panel wrapping apparatus 101. As such, in said embodiment, the control panel 108 may be in electrical communication with the control motor 106, the rotation controller 105, and the variable pressure solenoid valve 107, as well as an external power source, such as an electrical outlet (not shown) and any other electrically powered elements of the body panel wrapping apparatus 101. In an embodiment, the control panel 108 may be in electrical communication with a main power line (not shown) that is configured to engage with a standard 120V power outlet to power the panel wrapping apparatus 101. The control panel 108 may contain instrumentation and indicators to provide insight into current device operation. One such indicator may be an indicator light 108b that is configured to light up during certain parts of wrapping procedures to inform users of wrapping progress, relevant alerts, etc. The control panel 108 may also have additional ports, buttons, indicators and relevant control devices enclosed within.

The control panel may further comprise: an emergency stop mushroom pushbutton 108a that is configured to de-energize the body panel wrapping apparatus and disengage all existing forces and motions of each structure, a fault/condition indicator light 108b with audible buzzer that is configured to flash and buzz when the emergency stop mushroom pushbutton is pressed (e.g., when the apparatus 101 is in emergency stop mode), a main power indicator light 108c that is configured to light up when the machine is energized with A/C power, and a main power disconnect switch 108d configured to selectively connect the body panel wrapping apparatus 101 to a 220V AC power source. In and embodiment, the control panel 108 may further comprise: a wrap cycle start pushbutton 108e configured to be pressed to start a timed wrap cycle, a wrap cycle stop pushbutton 108f configured to be pressed to stop a timed wrap cycle, and a mode switch 108g configured to be pressed to selectively change the machine between an automatic and timed cycle mode for wrapping, and may also be used to selectively retract or extend the loading table 104 as disclosed herein. It should be understood that the buttons, switches and indicators present on the control panel may be varied in accordance with the needs of the application.

In an embodiment, the body panel wrapping apparatus 101 may be configured to either wrap a body panel automatically by rotating said body panel for a preprogrammed amount of time, or may be controlled manually by a user using the hereinabove disclosed buttons and the HMI control screen 150. As mentioned hereinabove, the control panel 108 may also further comprise an HMI control screen 150 that is configured to display timer control parameters and provide a means for the user/operator to change cycle time and the shrink wrap tension parameters as required, such as tension control buttons (not shown). Each of these control panel elements may be attached to a steel electrical enclosure 108h, which may contain additional structures, as will be disclosed hereinbelow.

In an embodiment, in order to suitably supply air pressure to operate the various pneumatic devices of the panel wrapping apparatus disclosed herein, a main air hose 123 may connect the pressure regulator to an external pressure line 127. The pressure regulator may be further connected to (e.g., in pneumatic communication with) each pneumatic device, accordingly (e.g., the pneumatic rail 104c, the compression cylinder 213 of FIG. 2D, the air cylinder 336 of FIG. 3, etc.). The main air hose 123 may be in pneumatic communication with the pressure regulator 126 such that the pressure regulator is configured to manage/regulate the main/master air pressure for all pneumatic devices on the panel wrapping apparatus 101. The pressure regulator may also be connected to a diverting air manifold or pipe tee which directs pressurized air to the pressure gauge and electrically controlled air solenoid valves, such as pressure gauge 107a and electrically controlled air solenoid valves (not shown). In an embodiment, the pressure gauge 107a may be configured to control the tension exerted on the air cylinder, whereas the bank of electrically controlled air solenoid valves may be configured to control the pneumatic rail 104c and the compression cylinder, such as compression cylinder 213 of FIG. 2D. The pressure gauge 107a may provide a visual indication of the pressure being exerted on the corresponding elements pneumatically connected to variable pressure solenoid valve 107. In an embodiment, the variable pressure solenoid valve 107 may be a special type of variable output air valve, wherein the variable pressure solenoid valve 107 is configured to receive a preset electrical signal from the PLC at a specific time interval to adjust the output pressure in proportion to the electrical signal being received. In an embodiment, the movement of the moving compression arm 102a and the sliding of the loading table 104 may be controlled by corresponding pneumatic devices in pneumatic communication with the external pressure line 127.

Each of the elements of the body panel wrapping apparatus 101 may be configured to attach to the body frame 109, at least indirectly, for secure attachment to the body panel wrapping apparatus 101 and thus each other. The body frame 109 may be made of any suitably strong material to support the weight of and suitably interconnect each of the herein described structures of the body panel wrapping apparatus 101. In an embodiment, the body frame 109 may be made of steel or another suitably strong metal that can support and interconnect the body panel wrapping apparatus elements. In said embodiment, the body frame 109 may comprise a plurality of hollow pipes having a suitable wall thickness to maintain the required strength of the body frame 109 while minimizing its weight and cost. Each applicable structure of the body panel wrapping apparatus 101 may be attached to the body frame 109 through suitable means, such as welding, screws, nuts and bolts, other suitable fasteners, etc. A swivel wheel 116 may be attached to each base corner 109b of the body frame 109 to allow for easy movement of the panel wrapping apparatus 101.

As mentioned hereinabove, the panel engaging portion 102 may be associated with the vertical drive shaft 110, such that the rotation of the vertical drive shaft 110 about a rotational axis 112 is configured to rotate the panel engaging portion 102, and thus the compression arms 102a, 102b about said rotational axis 112. This in turn results in the rolling and wrapping of a body panel compressed between the compression arms 102a, 102b. This rotation of the vertical drive shaft 110 to rotate the compression arms 102a, 102b may be powered by the attached control motor 106 or another suitable device/mechanism, which itself may be actuated by a user through manipulation of the hereinabove disclosed rotation controller 105. In an embodiment, when a wrapping material of the wrapping roll 103 is engaged with a body panel, the rotation of the panel engaging portion 102 about the rotational axis 112 causes rolling of the body panel and wrapping of the body panel with wrapping material from the wrapping roll.

In order to manipulate the moving compression arm 102a to facilitate engagement of the panel engaging portion with a suitable body panel, an additional control mechanism, in the form of a control pedal 111a, may be implemented. Manipulation of this control pedal 111a may result in actuation of a compression cylinder, such as compression cylinder 213 of FIG. 2D, and thus the compression or decompression of the compression arms 102a, 102b depending on when it is pressed. In an embodiment, pressing the control pedal 111a while the moving compression arm 102a is extended away from the stationary compression arm 102b will result in the moving of the compression arm 102a toward the stationary compression arm 102b. By having a control pedal 111a that a user may control using their foot, the user may have their hands free to manipulate a held body panel into the correct position for compression between the compression arms 102a, 102b, thus allowing a user to engage the body panel with the panel engaging portion 102 without the assistance of a secondary user.

The control pedal 111a may allow a single user to assume control over panel wrapping procedures. The control pedal 111a may be in electrical communication with the variable pressure solenoid valve, wherein the variable pressure solenoid valve 107 may be in pneumatic communication with a compression cylinder, such as compression cylinder 213 of FIG. 2D, such that manipulation of the control pedal 111a results in movement of the moving compression arm 102a. In an embodiment, the variable pressure solenoid valve 107 may also be in pneumatic communication with the pneumatic rail 104c, such that manipulation of the control pedal 111a results in movement of the loading table 104 as well, if applicable. The control pedal 111a may be attached to a pedal handle (not shown) to make moving the control pedal 111a around easier. An auxiliary pedal 111b may also be secured to the control pedal 111a, wherein the auxiliary pedal may be configured to initiate other apparatus operations, as needed. In an embodiment, the auxiliary pedal 111b may operate as an emergency power cut off, thus allowing a user close to the control pedal 111a to quickly and safely turn off the panel wrapping apparatus 101, while remaining sufficiently distant from the panel engaging portion 102. As is understood, the control pedal 111a may be in communication with the compression cylinder, such that an electrical signal generated from pressing control pedal 111a eventually leads to pneumatic operation of the disclosed compression cylinder, as described in greater detail hereinbelow.

It should be noted that each element of the panel wrapping apparatus 101 may be made of a suitable material to ensure device functionality as disclosed herein. For example, structures designed to support heavier loads, such as the body frame 109, may be made of more durable, high strength materials, such as metals like aluminum or steel. Structures designed to support moderate amounts of weight, such as the optional loading table may be made out of somewhat strong, but lightweight materials, such as wood or particle board, as the weights of generally lightweight vehicle panels do not typically warrant the use of high strength materials to support them. Each structure of the panel engaging portions 102 may be made of a high strength material, such as steel, with the exception of the outer portions of the compression arms 102a, 102b that directly contact a panel, which may be made of a softer, more flexible material, such as rubber, to ensure the vehicle panels aren't scratched or damaged upon compression.

Any controller-based devices (rotation controller 105, compression pedal 111a, auxiliary pedal 111b, etc.) may be made from the proper combination of metal, plastic, electrical components, etc., to allow them to be durable, while suitably performing their intended function (being used to control apparatus elements). Any tubing, wiring or other conventional connective elements may use any of the known flexible connective materials used for their equivalents. The wrapping roll 103 may use any suitable wrapping material (cellophane, shrink wrap, plastic wraps, straps, twine, etc.) that provides suitable strength to securely wrap each panel, as necessary. Any other structures may utilize appropriate materials such as metals, plastics, rubbers, etc. in order to suitably achieve their functions as described herein.

FIG. 2A illustrates the front view of the panel engaging portion 202 of the body panel wrapping apparatus, according to an aspect. FIG. 2B illustrates the front-left side perspective view of the panel engaging portion 202 of the body panel wrapping apparatus, according to an aspect. FIG. 2C illustrates the left side perspective view of the panel engaging portion 202 of the body panel wrapping apparatus, according to an aspect. FIG. 2D illustrates the top right perspective view of the panel engaging portion 202 of the body panel wrapping apparatus, according to an aspect. As disclosed hereinabove, in order to allow the body panel wrapping apparatus, such as body panel wrapping apparatus 101 of FIG. 1A, to selectively secure a body panel 220, during wrapping, a panel engaging portion 202 may be employed to clamp around said body panel 220. The panel engaging portion 202 may compress/sandwich/clamp the body panel 220 between a pair of compression arms 202a, 202b in order to securely engage with the body panel 220 prior to rolling/wrapping of said body panel 220 using the attached wrapping roll 203.

The panel engaging portion 202 may comprise a platform 202c having a nested arm travel cutout 202d, a compression cylinder 213 attached to the platform 202c, the compression cylinder 213 having a base housing 213a disposed above and attached to the platform 202c and a traveling piston 213b configured to partially nest within the base housing 213a, a stationary compression arm 202b attached to or otherwise associated with the platform 202c, and a moving compression arm 202a attached to the traveling piston 213b such that the compression arm is partially disposed within the arm travel cutout 202d. The panel engaging portion 202 may further comprise a rotational shaft 210 attached to the platform 202c, such that rotation of the rotational shaft 210 about a rotational axis 212 results in the rotation of the panel engaging portion 202 about said rotational axis 212, and thus the wrapping of a body panel secured between the compression arms 202a, 202b.

The vertical shaft 210 may comprise a rotational shaft 210a coupled to an air union, such as air union 410b of FIG. 4A, such that air supply hoses may travel through the rotational shaft 210 to the compression cylinder 213, wherein the air union is disposed above the rotational shaft 210a. As such, air supply hoses, such as air supply hoses 425a, 425b of FIG. 4A, may help provide a pneumatic connection between the variable pressure solenoid valve 207 and the compression cylinder 213 without being spun or bent by the rotation of the rotational shaft 210 and panel engaging portion 202. The connection between the air union and the rotational shaft 210a may allow pressurized air to travel from the air supply hoses to the compression cylinder 213. The opposing end of each air supply hose may terminate at the prior disclosed solenoid valve, such as the bank of electrically controlled solenoid valves, to facilitate manipulation of the moving compression arm 202a as disclosed herein. As such, the air supply hoses may be included in the outlet of the variable pressure solenoid valve 207.

In an embodiment, the platform 202c may have a round shape, wherein the platform 202c is configured to be rotated about a centrally disposed rotational axis 212 to rotate the attached compression arms 202a, 202b during wrapping. The arm travel cutout 202d nested within the platform 202c and the compression cylinder 213 attached to the platform 202c may be configured such that the moving compression arm 202a may be selectively moved toward the stationary compression arm 202b, thus allowing an object, such as a body panel, positioned between the moving compression arm 202a and the stationary compression arm 202b to be secured between the compression arms 202a, 202b.

In order to ensure that the panel that is being wrapped does not protrude beyond the perimeter of the work area of the panel engaging portion 202, a plurality of perimeter straps 214 may be employed around the perimeter of the panel engaging portion 202. These perimeter straps 214 may help to avoid the panels being wrapped from protruding outward and colliding with adjacent structures, such as variable pressure solenoid valve 207. These perimeter straps 214 may be secured to a first support post 209a-1 and a third support post 209a-3 and may travel around the second support post 209a-2, thus creating V-shaped perimeter barrier, as seen in FIG. 2A, wherein the support posts 209a-1, 209a-2, 209a-3 extend vertically upward from the below portions of the body frame 209. These perimeter straps 214 may be made out of a somewhat elastic material, such as rubber, in order to allow them to respond flexibly to impacts from body panels without being damaged or damaging a panel.

It should be understood that more or fewer perimeter straps 214 may be utilized in order to provide an optimized enclosure around the panels as they are being wrapped, protecting them from damage while still making them easy to access and manipulate as needed. In order to ensure that the compression arms 202a, 202b are capable of securely engaging with a body panel without damaging it, a suitable material may be utilized on the outer surface of each compression arms 202a, 202b. In an embodiment, the compression arms 202a, 202b may comprise a rubberized material configured to securely grip a panel upon being compressed together as disclosed herein, but without damaging the panel. It should also be understood that the compression arms 202a, 202b may be made of any suitable material(s) that would allow them to securely engage/compress a body panel during wrapping without damaging it. In an embodiment, the compression arms 202a, 202b may comprise an inner metal rod (not shown) surrounded by a suitably thick corresponding rubber outer coating 270, thus allowing each compression arm 202a, 202b to retain its shape while compressing a panel.

It should be understood that while the body panel wrapping apparatus, such as body panel wrapping apparatus 101 of FIG. 1A, may be shown in a “horizontal configuration” in FIGS. 2A-2D, in which the rotational axis 212 is perpendicular to the ground 260, and body panels, such as the bumper 220, are fed into the panel engaging portion 202 horizontally (e.g., left to right, in FIG. 1A), other embodiments may be possible as well. In an alternative embodiment, the panel engaging portion 202 of the body panel wrapping apparatus may be pivoted 90 degrees (e.g., rotating the panel engaging portion 202 from the perspective of FIG. 2A about 90 degrees clockwise or counterclockwise such that the rotational axis 212 is parallel with the ground), such that a body panel 220, such as a bumper, may be fed into the body panel wrapping apparatus 202 from above or below, rather than from the side. This “vertical configuration” of the body panel wrapping apparatus described hereinabove may be useful in applications in which feeding the body panel into the body panel wrapping apparatus from the left or right side is not practical, such as when horizontal clearance is limited. It should be understood that other elements, such as the wrapping roll 203 and its roll receptacle, may also need to be pivoted panel engaging portion 202 accordingly, such that the wrapping roll remains parallel with the rotational axis 212.

FIG. 3 illustrates the front perspective view of the air cylinder 336 and roll top keeper 337, according to an aspect. As disclosed hereinabove, the variable pressure solenoid valve, such as variable pressure solenoid valve 107 may be configured to control the amount of pressure that is applied to the shrink wrap roll 303 to restrict its ability to rotate freely, as well as moderate the pressure provided to control both the compression cylinder and pneumatic rail, such as the compression cylinder 213 of FIG. 2D and pneumatic rail 104c of FIG. 1C. In an embodiment, the shrink wrap roll/wrapping roll 303 may comprise a roll insert 303b and a wrapping material 303a rolled, wrapped, coiled or otherwise disposed around the roll insert 303b, wherein the wrapping material 303a may be applied to a body panel as the body panel is rotated by the panel engaging portion.

In an embodiment, the variable pressure solenoid valve may be in pneumatic communication with the prior disclosed pressure regulator, such as pressure regulator 126 of FIG. 1B to allow for the distribution of air pressure from an external pressure line, such as pressure line 127 of FIG. 1C, to each pneumatic element. In an embodiment, various functions and operations of the herein disclosed body panel wrapping apparatus may be reliant on pneumatic based devices, as disclosed hereinabove. Each of these pneumatic based devices may rely on this pressure source to provide them with the necessary pressure to operate correctly. As such, a pressure regulator may provide a suitable hub location for the connection of the various pneumatic elements to this external pressure line, as well as the variable pressure solenoid valve, such as variable pressure solenoid valve 107 of FIG. 1A.

The herein disclosed variable pressure solenoid valve may comprise several elements, all of which are in pneumatic and/or electrical communication with each other. The variable pressure solenoid valve may comprise a pressure gauge configured to control the shrink wrap roll tension via the disclosed air cylinder 336 and a bank of electrically controlled air solenoid valves (not shown) that control the pneumatic rail of the loading table and compression cylinder of the panel engaging portion. The variable pressure solenoid valve may be in electronic/electrical communication with the control panel, such as control panel 108 of FIG. 1B, and the HMI screen, such as HMI screen 150 of FIG. 1A, to facilitate adjustment of the pressure exerted on the shrink wrap roll 303 during wrapping and the corresponding time interval over which said pressure is applied. The variable pressure solenoid valve may further comprise air supply hoses (not shown) that are attached to the pressure gauge and the bank of electrically controlled solenoid valves to facilitate pneumatic communication between the variable control solenoid valve and the various pneumatically controlled elements and solenoid valve controlling cable (not shown) connected between the bank of electrically controlled solenoid valves and the control panel to facilitate electrical communication between these elements. It should be understood that the variable pressure solenoid valve may be in electrical/electronic communication with each of the controller elements (the compression pedal 111a of FIG. 1A, the rotation controller 105 of FIG. 1A and the control panel 108 of FIG. 1B, etc.) to facilitate proper communication between pneumatic (air pressure controlled elements) and electrical elements.

While the herein disclosed embodiments of the body panel wrapping apparatus may incorporate a plurality of elements that function as pneumatic devices, it should be understood that said elements need not be limited to being pneumatic devices in all embodiments. In an alternative embodiment, each of the pneumatic elements of the disclosed body panel wrapping apparatus may be replaced with a corresponding non-pneumatic, electrically controlled elements (motor/servo, etc.), or manually controlled elements, where applicable. This being said, pneumatic devices may be preferred to use for the disclosed compression cylinder, air cylinder 336 and the pneumatic rail, given the robust structure, ease of use and the reliability associated with pneumatic devices.

As disclosed hereinabove, the shrink wrap roll 303 may be pivotally engaged with the body frame 309 of the body panel wrapping apparatus, and the variable pressure solenoid valve may be configured to control the amount of pressure that is applied to the shrink wrap roll 303 to selectively restrict its ability to rotate/pivot freely. The resultant pressure on the shrink wrap roll 303 having its rotation at least partially restricted, while simultaneously being rotated by virtue of its attachment to a body panel being wrapped, creates tension to help snuggly wrap the body panel in wrapping from the shrink wrap roll 303. The tension applied to the shrink wrap roll 303 may be the result of the solenoid valve actuating or otherwise controlling the air cylinder 336. The variable pressure solenoid valve may vary the air pressure provided to the air cylinder to achieve the desired pressure. This air cylinder 336 may be associated with the body frame 309 and the roll top keeper 337 and configured to selectively manipulate (pull down) the roll top keeper 337 onto the shrink wrap roll 303 to restrict the shrink wrap roll's movement/rotation, as described hereinabove.

The amount of pressure and the time interval in which this pressure is applied may be controlled by the aforementioned PLC, and can be changed by the user/operator as required via the HMI screen. In an embodiment, the air cylinder 336 and the roll top keeper 337 together may be referred to as a roll receptacle 361, wherein the roll receptacle 361 is associated with the body frame 309 and configured to pivotally engage with and selectively compress a wrapping roll 303 to partially restrict said wrapping roll's rotation. As described hereinabove, in an embodiment, the variable pressure solenoid valve may be in pneumatic communication with the air cylinder 336 and in electrical communication with the HMI screen, such that a user may manipulate or otherwise interact with the HMI screen to control the air pressure supplied to the air cylinder 336 by the variable pressure solenoid valve.

FIG. 4A illustrates the front view of the rotation controller 405 and control motor 406 of the body panel wrapping apparatus, according to an aspect. FIG. 4B illustrates a side perspective view of the control panel 408, according to an aspect. FIG. 4C illustrates a front perspective view of the control panel 408 without a front cover, according to an aspect. In order to allow a user to suitably operate the body panel wrapping apparatus 401 to initiate panel wrapping, a plurality of controller devices may be provided for said user to manipulate. One such controller device may be the aforementioned rotation controller 405 disposed above the panel engaging portion 402 and adjacent to the control motor 406, as seen in FIG. 4A.

The rotation controller may have a plurality of control elements 405a, 405b, 405c, 405d to allow a user to control the operations of the body panel wrapping apparatus 401. In an embodiment, these control elements may include a start button 405a to initiate panel engaging portion 402 rotation, a stop button 405b to stop panel engaging portion 402 rotation, a directional dial 405c configured to allow a user to change the rotation directions of the panel engaging portion 402 rotation (clockwise/counterclockwise) and an emergency stop button 405d to stop all device operations immediately. It should be understood that different quantities/functions of buttons/dials/etc. may be provided on the rotation controller 405 based upon the type of panels being wrapped and their specific needs, as applicable

In order to facilitate engagement between the control motor 406 and the vertical shaft 410 and thus rotation of the panel engaging portion 402, a motor drive box 424 may be utilized. This motor drive box 424 may be covered by a protective steel case 424a and may be configured to allow the rotation of the control motor 406 to rotate the rotational shaft 410a about the rotational axis 412 of the panel engaging portion 402, through conventional drive mechanism techniques and components, such as gears, shafts, etc. This motor drive box 424 may be attached to the body frame 409, disposed above the panel engaging portion 402, below the control motor 406 and adjacent to the rotation controller 405.

As described hereinabove, in order to facilitate proper operation of the panel engaging portion 402, the control motor 406 may be directly engaged with/coupled to a gear box 428. A chain sprocket (not shown) may be mounted to an output shaft of the gearbox 428. A roller chain (not shown) may be configured to connect the chain sprocket to the secondary sprocket (not shown), wherein the secondary sprocket is mounted to the vertical shaft. The vertical shaft may pass through an upper mounted bearing and a lower mounted bearing such that it engages with the panel engaging portion 402, or more specifically, the platform of the panel engaging portion, such as platform 202c of FIG. 2D. Again, the electrical power provided to the control motor 406 for operation may be regulated via a variable power frequency inverter drive 435. As disclosed hereinabove, both the PLC 429 and the power frequency inverter drive 435 may be nested within the control panel 408, whereas the HMI 450 may be disposed on an external surface of the control panel 408 for easy access

As disclosed hereinabove, the vertical shaft 410 may comprise a rotational shaft 410a which rotates the panel engaging portion 402, and an air union 410b engaged with the rotational shaft 410a such that it does not rotate with the rotational shaft 410a. The air union 410b may be configured to facilitate the travel of the air supply hoses 425a, 425b between the bank of electrically controlled solenoid valves and the compression cylinder, such as compression cylinder 213 of FIG. 2D. In an embodiment, a first air supply hose 425a may be configured to provide pressurized air to the compression cylinder to extend the moving compression arm away from the stationary compression arm to release a panel held between the compression arms. In the same embodiment, a second air supply hose 425b may be configured to provide pressurized air to the compression cylinder to retract the moving compression arm to compress a panel between the compression arms. It should be understood that such a rotation controller 405 and control motor 406 may not be required in all embodiments, such as embodiments that may utilize manual rotation by a user to rotate the engaged panel (e.g., a manual crank mechanism).

In an alternative embodiment, the rotation controller 405 and control motor 406 may be replaced by a manual crank mechanism (not shown), such that the rotation of the panel engaging portion may be done by a user by hand. The utilization of a manual crank mechanism instead of a control motor may reduce the overall complexity and cost to operate the corresponding body panel wrapping apparatus, but may reduce the amount of automation enabled by said body panel wrapping apparatus. In an embodiment, utilizing a manual crank mechanism instead of a control motor/rotation controller, after compressing the body panel between the compression arms of the panel engaging portion 402, the user may rotate the manual cranking mechanism by hand to rotate the panel engaging portion and the attached body panel, wrapping the body panel in the attached wrapping as it rotates. Once the body panel is sufficiently wrapped, the user may simply stop operating the manual crank mechanism, and proceed with the removal of the wrapped body panel from the panel engaging portion 402 of the body panel wrapping apparatus.

FIGS. 5-10 illustrate the method of using the disclosed panel wrapping apparatus to wrap a bumper, according to several aspects. FIG. 5 illustrates the front perspective view of a bumper 520 being pre-heated in a panel oven 540, according to an aspect. In the present embodiments of FIGS. 5-10, the body panel being wrapped by the panel wrapping apparatus is a bumper 520, but it should be understood that any other suitable body panel may also be wrapped using the procedure outlined herein. In order to increase the flexibility of a bumper 520 or other body panel during packaging, said bumper 520 may be heated by placing it within a panel oven 540 at a set temperature for a set amount of time. By increasing the flexibility of a bumper or other body panel prior to wrapping, a tighter, more compact package may be formed without damaging the bumper 520 or body panel, thus increasing packing efficiency and reducing the resultant package size. A panel oven 540 or similar heating structure may be ideal for heating the body panel 520, as a result of said panel oven 540 providing a uniform heat distribution to the bumper 520, thus ensuring no portion of the bumper becomes significantly hotter than any other. In an alternative embodiment, other sources of heating may be utilized to increase the flexibility of the bumper 520 or other body panel during wrapping, including heating guns or fans, direct sunlight, etc. Following the pre-heating of the bumper 520, said bumper 520 may be engaged with the body panel wrapping apparatus to begin being rolled.

FIG. 6 illustrates a front perspective view of a user 621 inserting an end portion 620a of the bumper 620 between the compression arms 602a, 602b of the panel engaging portion 602 of the body panel wrapping apparatus, according to an aspect. As can be seen in FIG. 6, a user 621 may continue the wrapping process by lifting a bumper 620 to engage with the panel engaging portion 602 of the body panel wrapping apparatus. The user may tie or otherwise attach the wrapping material 603a of the wrapping roll 603 to the bumper 620, to allow the bumper 620 to be wrapped as the bumper 620 is rotated by the panel engaging portion 602. Prior to engagement with the bumper 620, the moving compression arm 602a and the stationary compression arm 602b are not compressed together, such that the panel engaging portion 602 is in a relaxed state. As can be seen in FIG. 6, the user 621 may manipulate various control elements on the body panel wrapping apparatus to begin operation of the body panel wrapping apparatus, and thus facilitating efficient wrapping the bumper 620.

With the bumper 620 lifted to engage with the panel engaging portion 602, the user 621 may move the bumper 620 such that an end portion 620a of the bumper 620 is disposed between the compression arms 602a, 602b. Upon properly positioning the end portion 620a of the bumper 620 between the compression arms 602a, 602b, the user 621 may step on the compression pedal 611a to actuate the aforementioned compression cylinder, such as compression cylinder 213 of FIG. 2D, and thus actuate the moving compression arm 602a to move the moving compression arm 602a toward the stationary compression arm 602b, thus sandwiching/compressing the end portion 620a of the bumper 620 between the compression arms 602a, 602b on the platform 602c. This effectively secures the bumper 620 to the panel engaging portion 602, thus allowing for the rotation of the platform 602c to spin the panel engaging portion 602, thus rolling the bumper 620, and also wrapping said bumper 620 as a result of the attachment of the bumper 620 to the wrapping roll 603.

Once the panel engaging portion 602 is compressed between the compression arms 602a, 602b, the user 621 may press the appropriate button on the rotation controller, such as rotation controller 405 of FIG. 4A, to begin rotation of the panel engaging portion 602. As described hereinabove, this rotation of the panel engaging portion is configured to roll the bumper 620 while simultaneously covering the bumper 620 in layers of wrapping material from the wrapping roll 603. With the initiation of the rotation of the panel engaging portion 602, potentially through the manipulation of a rotation controller, such as rotation controller 405 of FIG. 4A, the user 621 may step back and allow the panel wrapping apparatus to proceed through an automated portion of the panel wrapping procedure. It should be understood that the wrapping roll 603 may rotate as the body panel engaging portion 602 begins to rotate, as a result of the attachment of a loose end of the wrapping material 603a of the wrapping roll 603 to the bumper 620.

FIG. 7 illustrates a front perspective view of the panel engaging portion 702 being rotated to continually roll and wrap the bumper 720, according to an aspect. As described hereinabove, after the bumper 720 is engaged with the panel engaging portion 702 and the wrapping roll 703, the bumper 720 may be gradually rolled and wrapped into a compact package for easy shipping and storage. In an embodiment, while the bumper 720 is being rolled, a loading wall portion of the optional loading table, such as loading wall 104b of FIG. 1A, may help to provide a surface that prevents the currently unrolled portion of the bumper 720 from swinging around during wrapping. It should be understood that the support posts of the panel engaging portion, particularly the support post disposed on the same side of the body frame as the loading wall (e.g., the third support post 209a-3 of FIG. 2A), may also help to prevent the bumper 720 from swinging around unexpectedly during the rolling and wrapping process.

FIG. 8 illustrates a front perspective view of the rolled bumper 820 being continually rotated to provide additional layers of wrapping around the bumper 820, according to an aspect. After the bumper 820 has been completely rolled into a compact package, it may be rotated for several additional revolutions to provide additional layers of wrapping around it. These additional layers of wrapping may help protect the bumper 820 and keep it from breaking through the packaging during travel, temperature changes, etc. After providing a certain amount of additional wrapping layers around the bumper 820, the moving compression arm 802a may be moved away from the stationary compression arm 802b automatically to allow for easier removal of the bumper 820 from the compression arms 802a, 802b by hand. Despite the bumper 820 no longer being compressed between the compression arms 802a, 802b engaged with the platform 802c, after panel engaging portion 802 is returned to the relaxed position, said bumper 820 may remain attached to the compression arms 802a, 802b, by virtue of the wrapping material 803a forcing the bumper to maintain a certain shape and size that remains engaged with the outer surfaces of the compression arms 802a, 802b.

FIG. 9 illustrates a front perspective view of the compression arms 902a, 902b being partially disengaged from the wrapped bumper 920, according to an aspect. After the bumper has been fully wrapped, the moving compression arm 902a may be further adjusted to loosen the grip of the panel engaging portion 902 on the wrapped bumper 920 in preparation for removal of the wrapped bumper 920 from the panel wrapping apparatus 901. As disclosed hereinabove, a compression cylinder 913 attached to the platform 902c of the panel engaging portion 902 may be configured to facilitate adjustment of the moving compression arm 902a to loosen the grip of the panel engaging portion with the wrapped bumper 920. In an embodiment, the friction between the compression arms 902a, 902b on the platform 902c and the bumper 920 while the compression arms 902a, 902b are no longer actively compressing the bumper 920 may be sufficient for the bumper 920 to remain attached to the panel engaging portion 902, until the user attempts to remove it from the panel engaging portion 902.

In an embodiment, as the final layers of wrapping are being applied to the bumper 920, a loading table 904 may be slidably removed from its disposition directly below the panel engaging portion 902, and thus the wrapped bumper 920. By leaving the space below the now wrapped bumper 920 open, the user may easily place a cart, package or other suitable object directly below the wrapped bumper 920 for transport, storage, etc. In an embodiment, the loading table 904 may be moved automatically without user intervention, as a result of the programming of the body panel wrapping apparatus.

Upon performing a certain number of revolutions of the panel engaging portion 902 to achieve a desired thickness of wrapping material 903a around the outside of the bumper 920, the rotation of the panel engaging portion 902 may be stopped, either automatically as an aspect of system programming or manually at the discretion of the user. After stopping rotation, the user may cut/break the appropriate portion of the attached wrapping roll 903 to disconnect or otherwise disengage the wrapped bumper 920 from the wrapping roll 903. With the bumper 920 fully wrapped and disconnected from the wrapping roll 903, the bumper 920 may be removed from the panel wrapping apparatus by removing the wrapped bumper 920 from the panel engaging portion 902. In an embodiment, removal of the wrapped bumper 920 may be done by simply adjusting the moving compression arm 902a until the wrapped bumper 920 is loose enough to drop off naturally. In an alternative embodiment, removal of the wrapped bumper 920 may be done by adjusting the moving compression arm 902a until the wrapped bumper 920 is loose enough for a user to manually pull the wrapped bumper 920 off, thus ensuring a controlled release of the wrapped bumper 920 from the panel engaging portion.

FIG. 10 illustrates the top perspective view of a wrapped bumper 1020 placed within a box 1042 for shipping, according to an aspect. Upon the completion of the wrapping procedure steps outlined in FIGS. 5-9, the user may have a body panel 1020 encased in layers of wrapping material 1003a. As disclosed hereinabove, this wrapping material 1003a may be plastic wrap, shrink wrap, straps, twine, or any other suitable material configured to reversibly wrap the body panel 1020 into a small form factor without damaging it. By wrapping a body panel 1020 though folding, rolling, bending, as disclosed hereinabove, one or more of the dimensions of the body panel 1020 may be significantly reduced. In an embodiment, a body panel, such as a bumper 1020, having a length significantly greater than its width or height may be rolled in a smaller, cylindrical shape, thus significantly reducing its larger “length” dimension. While in this cylindrical shape, as shown in FIG. 10, the bumper 1020 may be easily fit into a small box 1042 having dimensions that do not result in increased shipping costs (e.g. within regulation sizes for standard packages).

In short, the wrapping process articulated in FIG. 5-10 may be summarized as comprising the following steps: obtaining a body panel, such as a bumper, attaching the body panel to the wrapping roll and moving it between the compression arms of the panel engaging portion, actuating the moving compression arm to selectively compress the body panel between the moving compression arm and the stationary compression arm, engaging the body panel with a wrapping roll, initiating rotation of the panel engaging portion, and thus rolling and wrapping the engaged body panel, continuing rolling the body panel until it is fully wrapped within wrapping from the wrapping roll, cutting, or otherwise disengaging the wrapping roll, such that the wrapped bumper is no longer attached to the wrapping roll, removing the body panel from the panel engaging portion, and, optionally, placing the wrapped bumper into a box for shipping.

This wrapping process articulated herein may be modified in light of the alternative embodiments detailed herein, as well as those that would be obvious in light of the disclosure (allowing for additional rotations of the panel engaging portion to achieve a thicker outer wrapping, further manipulating the compression arms to ease removal of the wrapped panel, etc.). Furthermore, each of the above steps may be modified to include additional details regarding the specific structures and elements used to perform each step (e.g., stepping on a compression pedal to actuate the movement of the moving compression arm toward the stationary compression arm to compress/sandwich the panel within the panel engaging portion, etc.) Additional steps prior to placing a body panel on the loading table to prepare said body panel for wrapping, such as preheating the body panel, as seen in FIG. 5, may also be utilized to make the body panel more flexible.

By following the steps articulated in FIG. 5-10 sequentially, a user may singlehandedly wrap a body panel, such as a bumper, into a compact package, quickly and efficiently. As described hereinabove, this wrapped bumper 1020 may be further packaged within conventional storage/transit containers to further protect it from damage, as necessary. As disclosed hereinabove, while the embodiments of FIG. 5-10 may only show a bumper being wrapped, other panels, such as vehicle side panels, may also be wrapped by following the same procedure. This wrapping procedure may be advantageous for a plurality of reasons, including decreasing shipping costs for transporting the resultant rolled parts (due to decreased object dimensions), particularly for international/overseas shipping, increasing panel wrapping efficiency/decreasing panel wrapping time requirements and decreasing labor demands, amongst other advantages.

FIGS. 11A-11D illustrate embodiments of program files utilized by the programmable logic controller of the body panel wrapping apparatus, according to an aspect. In order to facilitate the automation of the body panel wrapping apparatus as disclosed herein, the programmable logic controller, such as PLC 429 of FIG. 4C, may follow specific processes and procedures based on stored programs. The corresponding PLC program files may contain the logic/language required to instruct the programmable logic controller how to perform the various sequence functions to wrap a body panel or other part. One embodiment of a program file 1138 may be found in FIG. 11A, wherein a second embodiment of a program file 1139 may be found in FIGS. 11B-11D, which provides a program file split between FIGS. 11B-11D. Utilization of these program files may allow the PLC to actuate each element of the body panel wrapping apparatus, such as the compression cylinder, control motor, etc. to perform the required functions at the required times to facilitate wrapping of a body panel. For example, each program file 1138, 1139 may provide instructions for the operation of each controlled element, such as the compression cylinder 213 of FIG. 2D, air cylinder 336 of FIG. 3, the pneumatic rail 104c of FIG. 1C, etc., to ensure each element functions as needed during automated wrapping procedures and performs the required actions at the required times. These PLC program files may allow for the application of user input commands, to be used in conjunction with automatic processes to ensure proper, optimized wrapping of body panels or other parts.

It may be advantageous to set forth definitions of certain words and phrases used in this patent document. The term “couple” and its derivatives refer to any direct or indirect communication between two or more elements, whether or not those elements are in physical contact with one another. The term “or” is inclusive, meaning and/or. As used in this application, “and/or” means that the listed items are alternatives, but the alternatives also include any combination of the listed items.

The phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like.

Further, as used in this application, “plurality” means two or more. A “set” of items may include one or more of such items. The terms “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of,” respectively, are closed or semi-closed transitional phrases.

Throughout this description, the aspects, embodiments or examples shown should be considered as exemplars, rather than limitations on the apparatus or procedures disclosed. Although some of the examples may involve specific combinations of method acts or system elements, it should be understood that those acts and those elements may be combined in other ways to accomplish the same objectives.

Acts, elements and features discussed only in connection with one aspect, embodiment or example are not intended to be excluded from a similar role(s) in other aspects, embodiments or examples.

Aspects, embodiments or examples of the invention may be described as processes, which are usually depicted using a flowchart, a flow diagram, a structure diagram, or a block diagram. Although a flowchart may depict the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. With regard to flowcharts, it should be understood that additional and fewer steps may be taken, and the steps as shown may be combined or further refined to achieve the described methods.

Although aspects, embodiments and/or examples have been illustrated and described herein, someone of ordinary skills in the art will easily detect alternate of the same and/or equivalent variations, which may be capable of achieving the same results, and which may be substituted for the aspects, embodiments and/or examples illustrated and described herein, without departing from the scope of the invention. Therefore, the scope of this application is intended to cover such alternate aspects, embodiments and/or examples.

Claims

1. A body panel wrapping apparatus comprising:

a frame;

a roll receptacle associated with the frame, wherein the roll receptacle is configured to be pivotally engaged with a wrapping roll;

a panel engaging portion associated with the frame, wherein the panel engaging portion is configured to be selectively engaged with the body panel and selectively rotated about a rotational axis, the panel engaging portion comprising: a platform; a stationary compression arm attached to the platform; and a moving compression arm associated with the platform, wherein the moving compression arm is configured to be selectively moved toward the stationary compression arm to selectively compress the body panel between the stationary compression arm and the moving compression arm;

a control motor associated with the frame, wherein the control motor is configured to selectively rotate the panel engaging portion about the rotational axis;

wherein when a wrapping material of the wrapping roll is engaged with a body panel, the rotation of the panel engaging portion about the rotational axis causes rolling of the body panel and wrapping of the body panel with wrapping material from the wrapping roll.

2. The roll receptacle of claim 1 comprising an air cylinder associated with the frame and a roll top keeper associated with the air cylinder, wherein the air cylinder is configured to selectively adjust the roll top keeper to selectively restrict rotation of the wrapping roll.

3. The body panel wrapping apparatus of claim 2, further comprising a variable pressure solenoid valve associated with the frame, wherein the variable pressure solenoid valve is configured to be in pneumatic communication with the air cylinder and to selectively control an air pressure supplied to the air cylinder.

4. The body panel wrapping apparatus of claim 3, further comprising a human machine interface screen in electrical communication with the variable pressure solenoid valve, wherein the human machine interface screen is configured to be manipulated by a user to control the air pressure supplied to the roll receptacle by the variable pressure solenoid valve.

5. The body panel wrapping apparatus of claim 1, further comprising a compression cylinder attached to the platform and the moving compression arm, wherein the compression cylinder is configured to selectively move the moving compression arm toward the stationary compression arm to facilitate selective engagement of the panel engaging portion with the body panel.

6. The body panel wrapping apparatus of claim 5, further comprising a control pedal in communication with the compression cylinder, wherein the control pedal is configured to actuate the compression cylinder to selectively move the moving compression arm to selectively engage the body panel with the panel engaging portion.

7. The body panel wrapping apparatus of claim 1, further comprising a loading table associated with the frame, wherein the loading table is configured to provide support to the body panel prior to engagement between the body panel and the panel engaging portion.

8. The body panel wrapping apparatus of claim 1, wherein the rotational axis is perpendicular to the ground.

9. The body panel wrapping apparatus of claim 1, wherein the stationary compression arm and the moving compression arm each have a corresponding rubber outer coating.

10. A body panel wrapping apparatus comprising:

a frame;

a roll receptacle associated with the frame, wherein the roll receptacle is configured to be pivotally engaged with a wrapping roll;

a panel engaging portion associated with the frame, wherein the panel engaging portion is configured to be selectively engaged with the body panel and selectively rotated about a rotational axis, the panel engaging portion comprising: a platform; a stationary compression arm attached to the platform; and a moving compression arm associated with the platform, wherein the moving compression arm is configured to be selectively moved toward the stationary compression arm to selectively compress the body panel between the stationary compression arm and the moving compression arm;

wherein when a wrapping material of the wrapping roll is engaged with a body panel, the rotation of the panel engaging portion about the rotational axis causes rolling of the body panel and wrapping of the body panel with wrapping material from the wrapping roll.

11. The body panel wrapping apparatus of claim 10, further comprising a compression cylinder attached to the platform and the moving compression arm, wherein the compression cylinder is configured to selectively move the moving compression arm toward the stationary compression arm to facilitate selective engagement of the panel engaging portion with the body panel.

12. The body panel wrapping apparatus of claim 11, further comprising a control pedal in communication with the compression cylinder, wherein the control pedal is configured to actuate the compression cylinder to selectively move the moving compression arm to selectively engage the body panel with the panel engaging portion.

13. The body panel wrapping apparatus of claim 10, further comprising a loading table associated with the frame, wherein the loading table is configured to provide support to the body panel prior to engagement between the body panel and the panel engaging portion.

14. The body panel wrapping apparatus of claim 10, wherein the rotational axis is perpendicular to the ground.

15. The roll receptacle of claim 10 comprising an air cylinder associated with the frame and a roll top keeper associated with the air cylinder, wherein the air cylinder is configured to selectively adjust the roll top keeper to selectively restrict rotation of the wrapping roll.

16. The body panel wrapping apparatus of claim 10, wherein the stationary compression arm and the moving compression arm each have a corresponding rubber outer coating.

17. A body panel wrapping apparatus comprising:

a panel engaging portion, wherein the panel engaging portion is configured to be selectively engaged with a body panel and selectively rotated about a rotational axis, the panel engaging portion comprising: a platform; a stationary compression arm attached to the platform; and a moving compression arm associated with the platform, wherein the moving compression arm is configured to be selectively moved toward the stationary compression arm to selectively compress the body panel between the stationary compression arm and the moving compression arm;

wherein the rotation of the panel engaging portion about the rotational axis causes rolling of the body panel.

18. The body panel wrapping apparatus of claim 17, further comprising a compression cylinder attached to the platform and the moving compression arm, wherein the compression cylinder is configured to selectively move the moving compression arm toward the stationary compression arm to facilitate selective engagement of the panel engaging portion with the body panel.

19. The body panel wrapping apparatus of claim 18, further comprising a control pedal in communication with the compression cylinder, wherein the control pedal is configured to actuate the compression cylinder to selectively move the moving compression arm to selectively engage the body panel with the panel engaging portion.

20. The body panel wrapping apparatus of claim 17, wherein the rotational axis is perpendicular to the ground.