CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The benefit of priority to U.S. Provisional Patent Application No. 62/809,242 filed February 22, 2019, is hereby claimed and the disclosure is incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002] This disclosure relates generally to methods and systems for wrapping a sheet of material or materials and, more particularly, to methods and systems for automatically wrapping a sheet of material or materials, such as a ream of paper.

BACKGROUND

[0003] Standard ream wrapping of reams of paper, e.g., reams of paper having the dimensions in the range of about 8.5”x 1 1” up to 14”x 20”, is typically accomplished with a girth seal on a bottom of the ream. This process is done to maximize the speed at which the wrapping process can be performed.

[0004] The process for wrapping cutsize reams of paper, however, is not as feasible in folio ream applications, as the folio reams of paper are much larger than the cutsize reams of paper. Thus, the amount of unsupported paper from the folio ream is too great for the cutsize paper wrapping process. To avoid this problem, traditional folio wrappers place the girth seal on a top portion of the ream, which may be accomplished in a variety of different ways.

[0005] For example, existing systems for wrapping a flat sheet of material typically include one or more of a vacuum bar, a roller, or a brush, each of which operates across the ream to fold one or more portions of the wrap sheet during the wrapping process. Each of these devices requires the wrap sheet to have an optimal tension, such that the wrap sheet may respond well to changes in one or more of direction, speed, and/or position dictated by one or more of these devices. Flowever, in most existing systems, the various devices are not always able to maintain a desired tension and/or a required taut position of the wrap sheet during the wrapping process. As a result, sufficient wrapping of the sheet of material, such as a folio ream, is often not achieved, as deformations, bumps and/or wrinkles caused by lack of stiffness during the wrapping process are formed on the wrap sheet. This slows the entire wrapping process, reducing efficiency. SUMMARY OF THE DISCLOSURE

[0006] The present disclosure is directed to a method and apparatus for automatically wrapping a sheet of material. According to one aspect of the present disclosure, a method of automatically wrapping a folio ream comprises positioning a wrap sheet in a fully extended position and securing at least one robotic arm on at least one corner of the wrap sheet. The method also comprises controlling a tension of the wrap sheet via the at least one robotic arm, and simultaneously pulling the at least one corner of the wrap sheet via the at least one robotic arm to ensure a taut condition of the wrap sheet. The method still further comprises rotating one of a first flap or a second flap of the wrap sheet in a direction toward a top portion of the sheet of material via the at least one robotic arm, and then securing one of the first flap or the second flap of the wrap sheet to the top portion of the sheet of material via at least one robotic arm and simultaneously applying the same force to each corner of the wrap sheet to maintain the taut condition of the wrap sheet. The method also comprises rotating the other of the first portion or the second portion of the wrap sheet in a direction toward the top portion of the sheet of material via the at least one robotic arm and simultaneously applying the same force to the at least one corner of the wrap sheet to maintain the taut condition of the wrap sheet, and affixing the other of the first portion of the second portion of the wrap sheet to the second portion or the first portion, respectively, of the wrap sheet via the at least one robotic arm to form a seam on the top portion of the folio ream.

[0007] According to another aspect of the present disclosure, a system for automatically wrapping a sheet of material to form a seam comprises a first station having an infeed conveyor adapted to receive a sheet of material or materials, such as a folio ream. A second station is adjacent to the first station and has an intermediate conveyor, a wrap sheet disposed on the intermediate conveyor, and a robotic member. The robotic member interacts with portions of the wrap sheet to maintain a taut condition of the wrap sheet before and after the folio ream is driven onto and/or through the wrap sheet. In addition, the infeed conveyor is adapted to actuate the folio ream onto the wrap sheet. Further, the robotic member is adapted to rotate a first portion of the wrap sheet in a first direction and rotate a second portion of the wrap sheet in a second direction to secure the second portion of the wrap sheet to one of the top portion of the sheet of material or the first portion of the wrap sheet while simultaneously applying the same force at the same time on each portion of the wrap sheet to maintain the taut condition of the wrap sheet.

[0008] According to yet another aspect of the present disclosure, another method of automatically wrapping a sheet of material comprises aligning at least one robotic member to at least one area of the wrap sheet and controlling a tension of the wrap sheet via the at least one robotic member. The method further includes simultaneously pulling the at least one portion of the wrap sheet via the at least one robotic member to ensure a taut condition of the wrap sheet, and securing one of a first portion or a second portion of the wrap sheet to a portion of the sheet of material, such as the sheet of material via the at least one robotic member. At the same time, the robotic member applies the same force to the at least one corner of the wrap sheet to maintain the taut condition of the wrap sheet. The method also includes affixing an inner surface of one of the first portion or the second portion of the wrap sheet to an outer surface of the second portion or the first portion, respectively, of the wrap sheet via the at least one robotic arm to form a seam on a portion of the folio ream.

[0009] In further accordance with any one or more of the exemplary aspects, the methods and system for wrapping a folio ream of the present disclosure may include any one or more of the following preferred forms.

[0010] In some aspects, positioning a wrap sheet in an extended position may comprise positioning a wrap sheet on an intermediate conveyor, the wrap sheet positioned in a single plane parallel to a longitudinal axis of the intermediate conveyor. In addition, securing at least one robotic arm on at least one corner of the wrap sheet may comprise securing a plurality of arms having at least two robotic arms on at least two separate portions of the wrap sheet. Further, securing at least one robotic arm on at least one corner of the wrap sheet may comprise securing one of two robotic arms to two corresponding portions of the wrap sheet or four robotic arms of a plurality of robotic arms to four corresponding separate corners of the wrap sheet. Controlling a tension of the wrap sheet via the at least one robotic arm may comprise controlling a transversal tension of the wrap sheet and/or applying a same force at the same time to the two separate portions of the wrap sheet via the at least two robotic arms.

[0011] According to other aspects, the method may further comprise driving a sheet of material, such as a folio ream, onto the wrap sheet including moving the folio ream from an infeed conveyor to an intermediate conveyor immediately adjacent to the infeed conveyor on which the wrap sheet is positioned. In addition, simultaneously pulling the at least one corner of the wrap sheet via the at least one robotic arm to ensure a taut condition of the wrap sheet may comprise simultaneously pulling four corners of the wrap sheet with the same force at the same time via four robotic arms, each robotic arm corresponding to a separate corner of the wrap sheet. Further, rotating one of a first portion or a second portion of the wrap sheet in a direction toward a top portion of the folio ream with at least one robotic arm may comprise rotating the first portion of the wrap sheet in a clockwise direction with one of two robotic arms or four robotic arms, each arm secured to a separate portion of the lower flap of the wrap sheet. Still further, rotating one of a first portion or a second portion of the wrap sheet in a direction toward the top portion of the folio ream via the at least one robotic arm and simultaneously applying the same force to the at least one corner of the wrap sheet to maintain the taut condition of the wrap sheet may comprise rotating the second portion of the wrap sheet with one of two robotic arms or four robotic arms, each arm secured to a separate portion of the upper flap of the wrap sheet and applying the same force to each separate portion to maintain the taut condition.

[0012] According to still other aspects, the at least one robotic member may include four robotic arms secured to four corners of the wrap sheet. In addition, the intermediate conveyor may have a longitudinal axis, the wrap sheet may be disposed in a plane parallel to the longitudinal axis of the intermediate conveyor, and the at least one robotic member may move along the longitudinal axis of the intermediate conveyor. Further, the at least one robotic member may control a torque, a force, a position, and a speed of the wrap sheet.

[0013] According to still other aspects, the at least one robotic member may include a contact surface adapted to interact with the wrap sheet, and the contact surface may comprise a material having a softness the prevents any breaking or damage to the wrap sheet. Further, the at least one robotic member may include one or more of a gripping portion having one of at least one finger, or a vacuum portion or a pneumatic source. Also, the at least one robotic member may include at least one robotic arm having a base with a first arm portion pivotably coupled to the base, a second arm portion pivotably coupled to the first arm portion, and a third arm portion rotatably coupled to the second arm portion and including a contact surface adapted to interact with the wrap sheet. Still further, the first portion of the wrap sheet may be a lower portion of the wrap sheet, the second portion of the wrap sheet may be an upper portion of the wrap sheet, the first direction may be clockwise, and the second direction may be counterclockwise.

[0014] In still other aspects, aligning at least one robotic member on at least one corner of the wrap sheet may comprise securing four robotic arms to four corners of the wrap sheet. Further, controlling a tension of the wrap sheet via the at least one robotic member may comprise controlling one or more of a torque, a force, a position, and a speed of the wrap sheet via the at least one robotic member. In addition, the method may further comprise rotating one of the first portion of the wrap sheet or the second portion of the wrap sheet in a direction toward a top portion of the sheet of material via the at least one robotic member after simultaneously pulling the at least one corner of the wrap sheet via the at least one robotic member to ensure a taut condition of the wrap sheet. Still further, the method may still further comprise rotating the other of the first portion of the wrap sheet or the second portion of the wrap sheet in a direction toward a top portion of the sheet of material via the at least one robotic member and simultaneously applying the same force to the at least one corner of the wrap sheet to maintain the taut position of the wrap sheet after securing one of the first portion of the wrap sheet or the second portion of the wrap sheet to a portion of the sheet of material.

[0015] In still other examples, aligning at least one robotic member on at least one corner of the wrap sheet may include one or more of aligning a robotic member on each side of an intermediate conveyor or securing four robotic arms to four corners of the wrap sheet, the robotic arms working consecutively. Further, controlling a tension of the wrap sheet via the at least one robotic member may include controlling one or more of a torque, a force, a position, and a speed of the wrap sheet via the at least one robotic member.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Fig. 1 is a front, perspective view of a system for wrapping a sheet of material according to an aspect of the present disclosure;

[0017] Fig. 2 a front, perspective view of a portion of the system of Fig. 1 , with a sheet of material, such as a folio ream of paper, disposed on a wrap sheet;

[0018] Fig. 3 is another front, perspective view of a portion of the system of Fig. 1 ;

[0019] Fig. 4 is another front, perspective view of a portion of the system of Fig. 1 at a time different from the time depicted in Figs. 2 and 3;

[0020] Fig. 5A is a front view of a wrapped sheet of material according to an aspect of the present disclosure;

[0021] Fig. 5B is a front view of another wrapped sheet of material according to another aspect of the present disclosure;

[0022] Fig. 6 is a perspective view of an exemplary portion of a system for wrapping a sheet of material according to an aspect of the present disclosure;

[0023] Fig. 7 is another perspective view of another portion of the system of Fig. 6;

[0024] Fig. 8 is front perspective view of a portion of a robotic arm of the system of Fig. 6; and

[0025] Fig. 9 is a perspective view of an exemplary portion of another system for wrapping a sheet of material according to another aspect of the present disclosure. DETAILED DESCRIPTION OF THE DISCLOSURE

[0026] Generally, a system and method for automatically wrapping a sheet of material is disclosed. A wrap cycle of the present disclosure includes a method for automatically wrapping a sheet of material using one robotic arm or a plurality of robotic arms to maintain a taut position of a wrap sheet throughout an entire wrapping process. In this way, there is no, if only very minimal, creasing, marks, and/or other imperfections on the wrap sheet after the sheet of material is completely wrapped. As a result, the sheet of material or materials, such as the folio ream, is more stable on the pallet and the wrap sheet is less likely to tear or become further damaged during shipment and/or use. The following disclosure and claims set forth an automated process by which the sheet of material, such as the folio ream, is wrapped.

[0027] Referring now to Fig. 1 , a system 10 for automatically wrapping a sheet of material is depicted. The sheet of material may include one or more of a flat sheet of material, a ream of paper, a folio ream of paper, a plastic product having a flat sheet, more generally a plastic product and the like. While the following description generally refers to the sheet of material, such as the folio ream of paper, the flat sheet of material may alternatively include other reams of paper, a flat sheet of paper, other plastic products and the like, and/or any unit or article capable of being wrapped and still fall within the scope of the present disclosure. The system 10 includes a first station 12 having an infeed conveyor 14 adapted to receive a sheet of material, such as a folio ream 16. In this example, the folio ream 16 is disposed on a top portion of the infeed conveyor 14 before a method of wrapping the folio ream 16 occurs, as described more below.

[0028] A second station 18 is disposed adjacent to the first station 12 and includes an intermediate conveyor 20 adapted to receive a wrap sheet 22. The intermediate conveyor 20 is immediately adjacent to the infeed conveyor 14 and includes a longitudinal axis A. As depicted in Fig. 1 , the wrap sheet 22 is disposed on a top central portion of the intermediate conveyor 20 in a plane parallel to the longitudinal axis A. The infeed conveyor 14 is adapted to actuate the folio ream 16 onto the wrap sheet 22, as depicted in Fig. 2 and explained more below. Alternatively, the infeed conveyor 14 may be adapted to actuate the folio ream 16 through the wrap sheet 22, such as through a curtain of the wrap sheet, or any other manner of initially disposing the sheet of material, such as the folio ream of paper, toward the wrap sheet 22 to begin the wrapping process.

[0029] Although not depicted in Fig. 1 , one of skill in the art will appreciate that a third station may be disposed adjacent to and downstream from the intermediate conveyor 20. The third station may also include an output conveyor that receives a fully wrapped folio ream after wrapping is complete.

[0030] As further depicted in Fig. 1 , the second station 18 also includes a plurality of robotic members 24 including at least one robotic member 24. The at least one robotic member 24 includes a gripping portion 25 that contacts the wrap sheet 22 to maintain a taut condition of the wrap sheet 22 both before and after the folio ream 16 is driven onto the wrap sheet 22, for example.. In one example, and as depicted in Fig. 1 , the plurality of robotic members 24 includes four robotic members 24, such as robotic arms, each of which is secured to a corner 26 of the wrap sheet 22. Thus, in this example, the wrap sheet 22 includes four corners 26, and one robotic member 24 from the plurality of robotic members is attached to each of the four corners 26. The gripping portion 25 of each robotic member 24, such as the robotic arm 24, may include one or two fingers 27 (Figs. 2-3) that help secure and/or attach each robotic member 24 to the wrap sheet 22, for example. More specifically, and as depicted in Figs. 2-3, the gripping portion 25 of each robotic arm 24 includes two fingers 27 that grip each corner 26 of the wrap sheet 22. As explained more below, each robotic arm 24 may alternatively include another mechanism for one or more of interacting with and/or being secured to the wrap sheet 22 to maintain the taut position of the wrap sheet 22 and still fall within the scope of the disclosure. In any case, when the gripping portion 25, such as the fingers 27, contact and/or interact with the wrap sheet 22, the corresponding portion (or portions) of the wrap sheet 22 may be one or more of bent, moved, rotated, or inclined, for example, during wrapping.

[0031] In another example, the plurality of robotic members 24 includes two robotic members (see, e.g., Fig. 9) that are adapted to be secured to two corresponding perimeter portions of the wrap sheet 22. The perimeter portions of the wrap sheet 22 may include corners or any other perimeter portion, as explained more below. In still another example, the system 10 may include a single robotic member 24 (not depicted) and still fall within the scope of the present disclosure. In this example, the single robotic member 24 may perform one or more of the entire wrapping processes described more below.

[0032] Further, and as will be appreciated, the robotic arms 24 may include any robotic configuration capable of maintaining the taut position of the wrap sheet 22 during the wrapping cycle, for example, as explained more below. In one example, each robotic arm 24 may include a portal Cartesian arm or a gantry arm and still fall within the scope of the present disclosure. [0033] In operation, the wrap sheet 22 is first positioned in a fully extended position on the intermediate conveyor 20, as depicted in Fig. 1. In addition, at least one robotic member 24, such as the robotic arm 24 of the plurality of robotic members, is secured to at least one corner 26 of the wrap sheet 22. The tension of the wrap sheet 22, such as a transversal tension, is then controlled by the at least one robotic member 24. As a result, the wrap sheet 22 is in a taut position before the folio ream 16 is one or more of driven onto or driven through the wrap sheet 22 for wrapping.

[0034] Referring now to Figs. 2 and 3, the folio ream 16 has been driven onto the wrap sheet 22 by actuation of the infeed conveyor 14 (Fig. 1 ). While the folio ream 16 is being driven onto the wrap sheet 22, the at least one robotic member 24 simultaneously pulls the at least one corner 24 of the wrap sheet 22 to maintain the taut position of the wrap sheet 22. The robotic member 24 also simultaneously pulls the at least one corner 24 of the wrap sheet 22 to maintain the taut position of the wrap sheet 22 at other times during the wrapping process, such as when the folio ream 16 is moving on either the infeed conveyor 14 or the intermediate conveyor 20, as explained more below. In this example, the four robotic members 24 pull each corresponding corner 26 of the wrap sheet 24 to maintain the taut position, as desired. Alternatively, only one or two robotic members 24 may pull corresponding portions of the wrap sheet 24, such as the corners 26 or other perimeter portions, to maintain the taut position. More generally, more or fewer than four robotic members, such as one robotic member or six robotic members, may alternatively be used to maintain the taut position of the wrap sheet 22 throughout the wrapping process and still fall within the scope of the present disclosure.

[0035] In any case, the at least one robotic member 24 may pull the corner 26 or other perimeter portion in both a first direction B and a second direction C, such that the first and second directions are perpendicular to each other. For example, in Fig. 3, the first direction B is parallel to the longitudinal axis A (Fig. 1 ) of the intermediate conveyor 20, and the second direction C is a direction perpendicular to the first direction B, such that the taut and essentially wrinkle free position of the entire wrap sheet 22 is achieved and maintained. The first and second directions B, C may change relative to the longitudinal axis of A the intermediate conveyor 20 during the wrapping process (e.g., at other times), but the relative orientation of the first direction B and the second direction C remain perpendicular to each other at this stage in the process, for example. At other times during the wrapping process, the first direction B and the second direction C may not be perpendicular to each other. Instead, the first direction B and the second direction C may be directions less than 90 degrees or more than 90 degrees relative to each other depending upon the movement of the robotic member 24, for example.

[0036] Referring now to Fig. 4, the at least one robotic arm 24 rotates a first portion 28 of the wrap sheet 22, such as one or more of a first flap 28 or a lower flap 28, in a direction, such as a first direction or a clockwise direction, toward a top portion 30 of the folio ream 16. While the first direction is a clockwise direction in this example, the first direction may alternatively be other directions and still fall within the scope of the present disclosure. In one example, and as further depicted in Fig. 4, two robotic arms 24 are disposed opposite each other on either side of the lower flap 28 and together rotate the lower flap 28 in the clockwise direction. During rotation and while the folio ream 16 is moving with and/or on the intermediate conveyor 22, the robotic arms 24 apply the same force at the same time to the corners 26 of the lower flap 28 of the wrap sheet 22 to maintain the taut condition of the wrap sheet 22. After rotation, the robotic arms 24 secure the first portion, such as the lower flap 28, to the top portion 30 of the folio ream 16 (Fig. 5A) while again simultaneously applying the same force at the same time to each corner 26 of the wrap sheet 22 to maintain the taut position.

[0037] Still referring to Fig. 4, the at least one robotic arm 24 next rotates a second portion 32 of the wrap sheet 22, such as one or more of a second flap or an upper flap 32, in a second direction, such as a counterclockwise direction, toward the top portion 30 of the folio ream 16. In one example, and as again further depicted in Fig. 4, two other robotic arms 24 are disposed opposite each other on either side of the upper flap 32 and together rotate the upper flap 32 in the counterclockwise direction. During this rotation and again while the ream 16 is moving with the intermediate conveyor 22, these two robotic arms 24 again apply the same force at the same time to the two corners 26 of the upper flap 32 of the wrap sheet 22 to maintain the taut condition of the wrap sheet 22, as desired. These two robotic arms 24 then affix an inner surface 34 of the upper flap 32 to an outer surface 36 of the lower flap 28.

[0038] Referring now to Fig. 5A, a sectional view of a completely wrapped folio ream 16 is depicted. As depicted, the inner surface 34 of the upper flap 32 of the wrap sheet 22 is affixed to the outer surface 36 of the lower flap 28 of the wrap sheet. In this way, the wrap sheet 22 is disposed around the folio ream 16 essentially free of any imperfections or damage.

[0039] In another example, and referring back to Fig. 4, the at least one robotic arm 24 may first rotate the second portion 32 of the wrap sheet 22, such as the second flap 32 or the upper flap 32, in a second direction, such as a counterclockwise direction, toward the top portion 30 of the folio ream 16. While the second direction is a counterclockwise direction in this example, the second direction may alternatively be other directions and still fall within the scope of the present disclosure. In one example, and as again further depicted in Fig. 4, two other robotic arms 24 are disposed opposite each other on either side of the upper flap 32 and together rotate the upper flap 32 in the counterclockwise direction. During this rotation and again while the ream 16 is moving with the intermediate conveyor 22, these two robotic arms 24 again apply the same force at the same time to the two corners 26 of the upper flap 32 of the wrap sheet 22 to maintain the taut condition of the wrap sheet 22. The two robotic arms 24 then affix an inner surface 34 of the upper flap 32 to the top portion 30 of the folio ream 16 (Fig. 5B).

[0040] Still referring to Fig. 4, and in this same example, the at least one robotic arm 24 may next rotate the first portion 28 of the wrap sheet 22, such as a lower flap 28, in the first direction, such as a clockwise direction, toward a top portion 30 of the folio ream 16. The two robotic arms 24 are again disposed opposite each other on either side of the lower flap 28 and together rotate the lower flap 28 in the clockwise direction. During rotation and while the folio ream 16 is moving with the intermediate conveyor 22, the robotic arms 24 apply the same force at the same time to the corners 26 of the lower flap 28 of the wrap sheet 22 to maintain the taut condition of the wrap sheet 22. After rotation, the robotic arms 24 secure the first portion, such as the lower flap 28, to a top surface 37 of the second flap 32 of the wrap sheet 22 (Fig. 5B) while again simultaneously applying the same force at the same time to each corner 26 of the wrap sheet 22 to maintain the taut position.

[0041] Referring now to Fig. 5B, a sectional view of a completely wrapped folio ream 16 according to this example is depicted. As depicted, the inner surface 34 of the second flap 32 of the wrap sheet 22 is affixed to the top portion 30 of the folio ream 16, and the inner surface of the first flap 28 is affixed to the top surface 37 of the second flap 32 of the wrap sheet 22. In this way, the wrap sheet 22 is disposed around the folio ream 16 essentially free of any imperfections or damage.

[0042] Referring now to Figs. 6 and 7, an example plurality of robotic arms 24 is depicted. In this example, the plurality of robotic arms 24 includes four robotic arms 24, as depicted in Fig. 6. Specifically, two robotic arms 24 are disposed on either side of the intermediate conveyor 20 and outwardly extend from either side of a shoulder portion 42 coupled to a base 44. In Fig. 7, two of the robotic arms 24 disposed on one side of the intermediate conveyor 20 are depicted. Each robotic arm 24 interacts with portions of the wrap sheet 22. Specifically, in this example, the robotic arms 24 do not physically grip the wrap sheet 22, but include a contact surface 46 adapted to interact with the wrap sheet 22. The contact surface 46 comprises a material having a softness the prevents any breaking or damage to the wrap sheet. In addition, in this example, the contact surface 46 of the robotic arm 24 includes one or more of a vacuum or a pneumatic source, each of which applies the same force to a portion of the wrap sheet 22 at the same time to maintain the essentially taut position of the wrap sheet 22.

[0043] Referring now to Fig. 8, one robotic arm 24 of the robotic arms 24 of Figs. 6 and 7 is depicted. The robotic arm 24 includes a base 50 that couples to the shoulder 42 (Figs. 6- 7). A first arm portion 52 is pivotably coupled to the base 50 and a second arm portion 54 is pivotably coupled to the first arm portion 52. A third arm portion 56 is rotatably coupled to the second arm portion 54 and includes the contact surface 46. So configured, each of the first, second, and third arm portions 52, 54, and 56 of each robotic arm 24 may be actuated to rotate and/or move independently and/or relative to each other to provide a precise application of a pneumatic or vacuum force from one of the pneumatic source 58 or vacuum 60 disposed one of at or near the contact surface 46 of the robotic arm 24. In this way, the robotic arm 24 maintains the essentially taut position of the wrap sheet 22 during all phases of the wrapping cycle described above.

[0044] Further, while the robotic arm 24 of the Figs. 6-8 is depicted having one or more of the pneumatic source 58 or vacuum 60 disposed at the contact surface 46, it will be appreciated that the gripping member 25 (Figs. 1 -3) may alternatively and/or additionally be coupled to the contact surface 46 and still fall within the scope of the present disclosure. In this example, the gripping member 25 may include one or two fingers 27 and grip one or more portions of the wrap sheet 22, such as the corner portions 26, during wrapping.

Additionally, the robotic arm 24 may still use one or more of the pneumatic source 58 or vacuum 60 to also maintain the taut position of the wrap sheet 22 during wrapping along with the gripping member 25.

[0045] Referring now to Fig. 9, another system 100 for automatically wrapping a sheet of material 16 is depicted. The system 100 includes essentially all of the same parts as the system 10 described above, except the system 100 includes two robotic members 124, such as robotic arms, while the system 10 is depicted as having four robotic members 24, for example. As such, for the sake of brevity, parts of the system 100 identical to parts of system 10 will not be described in detail again and are numbered 100 more. [0046] More specifically, as depicted in Fig. 9, the system 100 for automatically wrapping the sheet of material 16, such as the folio ream of paper (as described above) includes a first station 1 12 having an infeed conveyor 1 14 adapted to receive the sheet of material 16 (not depicted). The system 100 further includes a second station 1 18 having an intermediate conveyor 120 adapted to receive a wrap sheet 122.

[0047] As further depicted in Fig. 9, the system 100 also includes two robotic members 124, such as a pair of robotic arms 124, adapted to be secured to and/or interact with the wrap sheet 122 to wrap the sheet of material 16. As with the robotic members 24 of Figs. 1 - 8, each robotic member 124 includes a gripping portion 125 that may include fingers 27 (Figs. 2-3). Alternatively, the gripping portion 125 may include a pneumatic source 158 or a vacuum 160 to help maintain a position of the wrap sheet 22, 122 during the wrapping process.

[0048] More specifically, and like the robotic arm 24, the robotic arms 124 each include a base 150 that couples to a shoulder 142. A first arm portion 152 is pivotably coupled to the base 150 and a second arm portion 154 is pivotably coupled to the first arm portion 152. A third arm portion 156 is rotatably coupled to the second arm portion 154 and includes a contact surface 146. So configured, each of the first, second, and third arm portions 152,

154, and 156 of each robotic arm 124 may be actuated to rotate and/or move independently, consecutively, and/or relative to each other. In this way, the robotic arms 124 provide a precise application of a pneumatic or vacuum force from one of the pneumatic source 158 or the vacuum 160 disposed one of at or near the contact surface 146 of the robotic arm 124. The two robotic arms 124 are able to wrap the sheet of material 122 while maintaining an essentially taut position of the wrap sheet 122, as needed during the wrapping methods described above.

[0049] Further, while the robotic arm 124 of Fig. 9 is depicted having one or more of the pneumatic source 158 or vacuum 160 disposed at the contact surface 146, it will be appreciated that the gripping member 125 may alternatively and/or additionally be coupled to the contact surface 146 and still fall within the scope of the present disclosure. In this example, the gripping member 125 may include one or two fingers 27 (Fig. 2-3) and grip one or more portions of the wrap sheet 122, such as the corner portions or perimeter portions, during wrapping. Additionally, the robotic arm 124 may still use one or more of the pneumatic source 158 or vacuum 160 to also maintain the taut position of the wrap sheet 122 during wrapping along with the gripping member 125. [0050] So configured, the system 100 of wrapping the sheet of material 16 is capable of implementing the same methods of the system 10 described above. In addition, the system 100 also enables the sheet of material 16 to be wrapped in the wrap sheet 122 by the robotic members 124 while the sheet of material 16 is moving on the intermediate conveyor, also like the system 10 described above.

[0051] Further, in one example, the robotic members 124 are initially disposed on either side of the intermediate conveyor 120, at a center area of either side of the intermediate conveyor 120. The robotic members 124 are movable along the longitudinal axis B of the intermediate conveyor 120. Upon beginning the wrapping process, the robotic members 124 may first together move along the longitudinal axis B toward the first flap 28 (Fig. 4) of the wrap sheet 22, 122 at the same time and the same speed. Upon reaching the sides of the first flap 28, the robotic members 124 may then move the first flap 28 of the wrap sheet 122, such as rotate the first flap 28 in clockwise direction, to secure the first flap 28 to a portion of the sheet of material 16. While moving the first flap of the wrap sheet 122, each robotic member 124 disposed on either side of the intermediate conveyor 120 is moving from being disposed on either side of the first flap 28 of the wrap sheet 122 to the center area on either side of the intermediate conveyor 120.

[0052] The robotic members 124 next move from about the center area of either side of the intermediate conveyor 120 along the longitudinal axis B toward the second flap 32 of the wrap sheet 22, 122, again at the same time and the same speed. Upon reaching the sides of the second flap 32, the robotic members 124 may then move the second flap 32 of the wrap sheet 122, such as rotate the second flap 32 in a counterclockwise direction, to secure the second flap to a top portion 36 (Fig. 4) of the first flap 28 to form a seam on a top area of the sheet of material 16.

[0053] Alternatively, in another example, upon beginning the wrapping process the robotic members 124 may first move together along the longitudinal axis B toward the second flap 32 of the wrap sheet 22 ,122 at the same time and at the same speed. Upon reaching the sides of the second flap 32, the robotic members 134 then move the second flap 32 in a second direction, such as a counterclockwise direction, to secure the second flap 32 to a top portion of the sheet of material 16, such as the folio ream of paper. While moving the second flap 32 of the wrap sheet 122, each robotic member 124 disposed on either side of the intermediate conveyor 120 is moving from being disposed on either side of the second flap 32 of the wrap sheet 122 to the center area on either side of the intermediate conveyor 120. [0054] The robotic members 124 next move from about the center area of either side of the intermediate conveyor 120 along the longitudinal axis B toward the first flap 28 of the wrap sheet 22, 122, again at the same time and the same speed. Upon reaching the sides of the first flap 28, the robotic members 124 may then move the first flap 28 of the wrap sheet 122, such as rotate the first flap 28, in a clockwise direction, to secure the first flap to a top portion 37 (Fig. 4) of the second flap 32 (Fig. 5B) to form a seam on a top area of the sheet of material 16.

[0055] In view of the foregoing, one of skill in the art will appreciate the many advantages of the method and systems 10, 100 of automatically wrapping a folio ream of the present disclosure. For example, because the at least one robotic member 24, 124 maintains the essentially taut position of the wrap sheet 22, 122 as desired throughout the wrapping cycle, the wrap sheet 22, 122 is virtually wrinkle free and does not include any damage to any edge, border or corner of the folio ream 16. As a result, there is no need to manually correct any problems, e.g., wrinkles, marks, at any time during the wrapping of the folio ream, saving time and costs for the wrapping process. Further, also because the at least one robotic member 24, 124 maintains the taut position of the wrap sheet 22, 122 there is no misalignment of any edge of the wrap sheet 22, 122 that conventional devices used to fold the wrap sheet 22, 122 produce. Thus, for at least the foregoing reasons, the new methods and system of automatically wrapping a sheet of material, such as a folio ream, is more efficient and effective in creating a wrapped flat sheet of material 16 in which the wrap sheet 22, 122 is essentially free of any wrinkles, misalignment, or damage.

[0056] The following additional considerations apply to the foregoing discussion.

Throughout this specification, plural instances may implement components, operations, or structures described as a single instance. Although individual operations of one or more methods are illustrated and described as separate operations, one or more of the individual operations may be performed concurrently, and nothing requires that the operations be performed in the order illustrated. Structures and functionality presented as separate components in example configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements fall within the scope of the subject matter herein.

[0057] Some implementations may be described using the expression“coupled” along with its derivatives. For example, some implementations may be described using the term “coupled” to indicate that two or more elements are in direct physical or electrical contact. The term“coupled,” however, may also mean that two or more elements are not in direct contact with each other, but yet still co-operate or interact with each other. The

implementations are not limited in this context.

[0058] As used herein, the terms“comprises,”“comprising,”“includes,”“incl uding,”“has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary,“or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0059] In addition, use of the“a” or“an” are employed to describe elements and components of the implementations herein. This is done merely for convenience and to give a general sense of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

[0060] Further, while particular implementations and applications have been illustrated and described, it is to be understood that the disclosed implementations are not limited to the precise construction and components disclosed herein. Various modifications, changes and variations, which will be apparent to those skilled in the art, may be made in the arrangement, operation and details of the methods and/or systems disclosed herein without departing from the spirit and scope defined in the appended claims.