Dynamic adjustment of wrap force parameter responsive to monitored wrap force and/or for film break reduction
A method, apparatus and program product monitor a wrap force during a wrap cycle to dynamically control the dispense rate of a packaging material dispenser to meet a desired containment force to be applied to a load. A conversion may be performed between wrap force and containment force for the monitored wrap force or a containment force parameter to facilitate the performance of a comparison between the monitored wrap force and a containment force parameter associated with the desired containment force to be applied to the load. A wrap force parameter may also be dynamically adjusted, and in some instances, the dynamic adjustment may be responsive to monitored wrap force, and may be used to meet a load containment force requirement for a load. In other instances, the dynamic adjustment may be responsive to monitored packaging material breaks to reduce the occurrence of packaging material breaks.
1. An apparatus for wrapping a load supported by a load support with packaging material, the apparatus comprising:
a packaging material dispenser for dispensing packaging material to the load, wherein the packaging material dispenser and the load support are adapted for rotation relative to one other; and
a controller coupled to the packaging material dispenser, wherein the controller determines a containment force parameter related to a desired containment force to be applied to the load during at least a portion of a wrap cycle and initiates the wrap cycle to wrap the load with packaging material dispensed from the packaging material dispenser during relative rotation between the packaging material dispenser and the load support, wherein the controller further, during the initiated wrap cycle, monitors a wrap force applied to the load by the packaging material during the relative rotation, performs a comparison between the monitored wrap force and the containment force parameter after a conversion between wrap force and containment force is performed for the monitored wrap force or the containment force parameter, and dynamically controls a dispense rate of the packaging material dispenser during the wrap cycle based on the comparison between the monitored wrap force and the containment force parameter.
2. The apparatus of claim 1 , wherein the containment force parameter comprises a desired incremental containment force to be applied to the load by each layer of packaging material to meet a containment force requirement for the load, and wherein the controller performs a conversion between wrap force and containment force by converting the monitored wrap force to a monitored incremental containment force, and performs the comparison by comparing the monitored incremental containment force to the desired incremental containment force.
3. The apparatus of claim 1 , wherein the containment force parameter comprises a desired incremental containment force to be applied to the load by each layer of packaging material to meet a containment force requirement for the load, and wherein the controller performs a conversion between wrap force and containment force by converting the desired incremental containment force to a desired wrap force, and performs the comparison by comparing the monitored wrap force to the desired wrap force.
4. The apparatus of claim 1 , wherein the controller dynamically controls the dispense rate of the packaging material dispenser during the wrap cycle by:
controlling the dispense rate of the packaging material dispenser during the relative rotation based at least in part on a wrap force parameter; and
dynamically and automatically adjusting the wrap force parameter based on the comparison between the monitored wrap force and the containment force parameter.
5. The apparatus of claim 4 , wherein the controller monitors the wrap force by determining a wrap force proximate an initial contact between the packaging material and a corner of the load, and dynamically and automatically adjusts the wrap force parameter by adjusting the wrap force parameter based at least in part on the determined wrap force proximate the initial contact between the packaging material and the corner of the load.
6. The apparatus of claim 4 , wherein the controller monitors the wrap force by determining an average wrap force, a minimum wrap force or a maximum wrap force over a full revolution, and dynamically and automatically adjusts the wrap force parameter by adjusting the wrap force parameter based at least in part on the determined average wrap force, minimum wrap force or maximum wrap force.
7. The apparatus of claim 4 , wherein the controller i further dynamically and automatically adjusts a layer parameter based on the comparison between the monitored wrap force and the containment force parameter to maintain the desired containment force in response to adjusting the wrap force parameter.