Pallet wrapping system with intelligent monitoring
View Patent ↗A monitoring system for wrapping a pallet with a pallet wrapping system, at least two encoders, and a control box. The pallet wrapping system has a spool that dispenses stretch film and a pre-stretch machine operably coupled to the pallet wrapping system and configured to elongate the stretch film. The at least two encoders are affixed to the pre-stretch machine. A first of the at least two encoders is configured to measure a length of stretch film entering the pre-stretch machine and a second is configured to measure a length of stretch film exiting the pre-stretch machine. The control box is communicatively coupled to the at least two encoders and configured to collect data regarding the pallet wrapping system and transmit the data over a wireless connection to a central processor configured to gather the data.
1. A monitoring system for wrapping a pallet, comprising: a pallet wrapping system having a spool configured to dispense stretch film, a pre-stretch machine operably coupled to the pallet wrapping system and configured to elongate the stretch film, and a pallet platform configured to support a palletized load as the stretch film is wrapped around the palletized load; at least two encoders affixed to the pre-stretch machine, wherein a first encoder of the at least two encoders is configured to measure a length of stretch film entering the pre-stretch machine and a second encoder of the at least two encoders is configured to measure a length of stretch film exiting the pre-stretch machine; and a control box communicatively coupled to the at least two encoders and configured to collect data regarding the pallet wrapping system and transmit the data over a cellular connection to a central processor configured to gather the data, the data including characteristics of the pallet wrapping system's operation sufficient to calculate at least the following measurements: a weight of stretch film wrapped around each pallet; a number of times the stretch film is wrapped around each pallet; a length of stretch film pulled into the pre-stretch machine per pallet; a length of stretch film applied to each pallet; an amount of stretch film remaining on a roll of stretch film when the roll of stretch film is replaced; an amount of time for the pallet wrapping system to wrap each pallet; and a number of web breaks in a specified time period; wherein each of the measurements has a corresponding range of acceptable values and the monitoring system is configured to notify a third party when any of the measurements leaves the corresponding range of acceptable values wherein the at least one encoder is affixed to a door of the pre-stretch machine.
2. The monitoring system of claim 1 , wherein the measurements further include an amount of stretch film available to a user of the pallet wrapping system for wrapping one or more palletized loads.
3. The monitoring system of claim 1 , wherein the control box is further configured to receive a selected configuration of the measurements for wrapping the palletized load from a user of the pallet wrapping system and implement the selected configuration in wrapping the palletized load.
4. A monitoring system for wrapping a pallet, comprising: a pallet wrapping system having a spool configured to dispense stretch film and a pre-stretch machine operably coupled to the pallet wrapping system and configured to elongate the stretch film; at least two encoders affixed to the pre-stretch machine, wherein a first encoder of the at least two encoders is configured to contact and measure a length of stretch film entering the pre-stretch machine and a second encoder of the at least two encoders is configured to contact and measure a length of stretch film exiting the pre-stretch machine; and a control box configured to collect data regarding the pallet wrapping system and transmit the data over a wireless connection to a central processor configured to gather the data, the data including characteristics of the pallet wrapping system's operation sufficient to calculate at least the following measures: a weight of stretch film wrapped around each pallet; a length of stretch film pulled into the pre-stretch machine per pallet; a length of stretch film applied to each pallet; and an amount of stretch film remaining on a roll of stretch film when the roll of stretch film is replaced; wherein each of the measurements has a corresponding range of acceptable values and the monitoring system is configured to notify a third party when any of the measurements leaves the corresponding range of acceptable values wherein the at least one encoder is affixed to a door of the pre-stretch machine.
5. The monitoring system of claim 4 , wherein the wireless connection is a cellular connection.
6. The monitoring system of claim 4 , wherein the measurements further include an amount of time for the pallet wrapping system to wrap each pallet.
7. The monitoring system of claim 4 , wherein the measurements further include a number of web breaks in a specified time period.
8. The monitoring system of claim 4 , wherein the measurements further include a number of times the stretch film is wrapped around each pallet.
9. A monitoring system for wrapping a pallet, comprising: a pallet wrapping system having a pre-stretch machine configured to elongate stretch film; at least one encoder configured to contact the stretch film and measure a length of the stretch film passing the at least one encoder; and a control box configured to collect data regarding the pallet wrapping system, the data including characteristics of the pallet wrapping system's operation sufficient to calculate at least the following measurements: a length of stretch film pulled into the pre-stretch machine per pallet; and a length of stretch film pulled out of the pre-stretch machine per pallet; wherein each of the measurements has a corresponding range of acceptable values and the monitoring system is configured to notify a third party when any of the measurements leaves the corresponding range of acceptable values wherein the at least one encoder is affixed to a door of the pre-stretch machine.
10. The monitoring system of claim 9 , wherein the control box is configured to transmit the data over a wireless connection to a central processor configured to gather the data.
11. The monitoring system of claim 9 , wherein the measurements further include a weight of stretch film wrapped around each pallet.
12. The monitoring system of claim 9 , wherein the measurements further include an amount of stretch film remaining on a roll of stretch film when the roll of stretch film is replaced.
13. The monitoring system of claim 9 , wherein the measurements further include an amount of stretch film available to a user of the monitoring system.
14. The monitoring system of claim 9 , wherein the measurements further include an amount of time for the pallet wrapping system to wrap each pallet.
15. The monitoring system of claim 9 , wherein the measurements further include a number of web breaks in a specified time period.
16. The monitoring system of claim 9 , wherein the measurements further include a number of times the stretch film is wrapped around each pallet.
17. The monitoring system of claim 9 , wherein the monitoring system is further configured to receive a selected configuration of the measurements for wrapping the palletized load from a user of the pallet wrapping system and implement the selected configuration in wrapping the palletized load.
18. The monitoring system of claim 9 , wherein the at least one encoder is at least two encoders affixed to the pre-stretch machine, wherein a first encoder of the at least two encoders is configured to measure a length of stretch film entering the pre-stretch machine and a second encoder of the at least two encoders is configured to measure a length of stretch film exiting the pre-stretch machine, wherein the control box is communicatively coupled to the at least two encoders.
19. The monitoring system of claim 9 , wherein the wireless connection is a cellular connection.