Low profile conveyor for use in stretch wrapping operations

Abstract

Apparatuses and related methods of use are provided for the accumulation and wrapping of palletized loads with packaging material. In an exemplary embodiment of the present disclosure, the apparatus includes a low profile conveyor having non-powered conveying elements. In another embodiment, the apparatus is a stretch wrapping system for wrapping palletized loads. The stretch wrapping system may include a dispenser, a means for providing relative rotation between the dispenser and the load to be wrapped, a low profile conveyor, and a powered pusher assembly for moving the loads.

1 . A low profile conveyor, comprising: 
 at least two non-powered conveyor elements, each conveyor element having a longitudinal axis and including an inner side rail, an outer side rail, and a conveying surface formed by a plurality of rolling elements positioned between the side rails, wherein the longitudinal axis of one of the conveyor elements is parallel to the longitudinal axis of the other of the conveyor elements; and    a base surface positioned between the conveyor elements.    
   
   
       2 . The low profile conveyor of  claim 1 , wherein the base surface is the ground.  
   
   
       3 . The low profile conveyor of  claim 1 , wherein the conveying surface of each of the at least two conveyor elements is between about 3.5 inches and about 0.5 inch above the base surface.  
   
   
       4 . The low profile conveyor of  claim 3 , wherein the conveying surface of each of the at least two conveyor elements is approximately 1 inch above the base surface.  
   
   
       5 . The low profile conveyor of  claim 1 , further comprising a guide element.  
   
   
       6 . The low profile conveyor of  claim 5 , wherein the guide element includes a raised structure positioned between the at least two conveyor elements.  
   
   
       7 . The low profile conveyor of  claim 6 , wherein the raised structure is centered between the at least two conveyor elements.  
   
   
       8 . The low profile conveyor of  claim 6 , wherein the raised structure extends a first distance above the base surface and the at least two conveyor elements extend a second distance above the base surface, wherein the first distance is different from the second distance.  
   
   
       9 . The low profile conveyor of  claim 8 , wherein the first distance is less than the second distance.  
   
   
       10 . The low profile conveyor of  claim 1 , wherein the conveyor is configured to receive a load from a pallet truck.  
   
   
       11 . The low profile conveyor of  claim 10 , wherein the pallet truck includes forks configured to support a base of a pallet a first distance from the base surface, wherein the at least two conveyor elements extend a second distance above the base surface, and wherein the second distance is less than the first distance.  
   
   
       12 . The low profile conveyor of  claim 1 , wherein the at least two conveyor elements are spaced to permit the passage of pallet truck forks between them.  
   
   
       13 . The low profile conveyor of  claim 1 , wherein the rolling elements include rolling surfaces mounted on shafts.  
   
   
       14 . The low profile conveyor of  claim 1 , further comprising a pusher assembly for pushing a load on the conveying surfaces of the at least two conveyor elements.  
   
   
       15 . The low profile conveyor of  claim 14 , wherein the pusher assembly includes an L-shaped pusher arm.  
   
   
       16 . The low profile conveyor of  claim 15 , wherein the pusher arm is rotatable.  
   
   
       17 . The low profile conveyor of  claim 15 , wherein the pusher arm is rotatable between an upright, vertical position and a lowered, horizontal position.  
   
   
       18 . The low profile conveyor of  claim 15 , wherein the pusher assembly further includes a second pusher arm.  
   
   
       19 . The low profile conveyor of  claim 18 , wherein the pusher arms are linked to move together.  
   
   
       20 . The low profile conveyor of  claim 1 , wherein the base surface includes a base plate.  
   
   
       21 . The low profile conveyor of  claim 20 , wherein the at least two conveyor elements are mounted on the base plate.  
   
   
       22 . The low profile conveyor of  claim 1 , wherein the base surface includes at least one rolling plate.  
   
   
       23 . The low profile conveyor of  claim 22 , wherein the at least one rolling plate is positioned on a base plate.  
   
   
       24 . The low profile conveyor of  claim 23 , wherein the at least two conveyor elements are mounted on the base plate.  
   
   
       25 . The low profile conveyor of  claim 23 , further including a third and fourth conveyor elements.  
   
   
       26 . A stretch wrapping system for wrapping palletized loads, comprising: 
 a dispenser for dispensing packaging material;    means for providing relative rotation between the dispenser and a load to wrap packaging material around the load;    a low profile conveyor comprising at least two conveyor elements, each conveyor element having a longitudinal axis and including an inner side rail, an outer side rail, and a conveying surface formed by a plurality of rolling elements positioned between the side rails, wherein the longitudinal axis of one of the conveyor elements is parallel to the longitudinal axis of the other of the conveyor elements, and a base surface positioned between the conveyor elements; and    a powered pusher assembly for moving the load on the conveying surfaces of the at least two conveyor elements.    
   
   
       27 . The stretch wrapping system of  claim 26 , wherein the at least two conveyor elements are non-powered.  
   
   
       28 . The stretch wrapping system of  claim 26 , wherein the conveying surface of each of the at least two conveyor elements is between about 3.5 inches and about 0.5 inch above the base surface.  
   
   
       29 . The stretch wrapping system conveyor of  claim 28 , wherein the conveying surface of each of the at least two conveyor elements is approximately 1 inch above the base surface.  
   
   
       30 . The stretch wrapping system of  claim 26 , wherein the low profile conveyor further includes a guide element.  
   
   
       31 . The stretch wrapping system of  claim 30 , wherein the guide element includes a raised structure positioned between the at least two conveyor elements.  
   
   
       32 . The stretch wrapping system of  claim 31 , wherein the raised structure is centered between the at least two conveyor elements.  
   
   
       33 . The stretch wrapping system of  claim 31 , wherein the raised structure extends a first distance above the base surface and the at least two conveyor elements extend a second distance above the base surface, wherein the first distance is different from the second distance.  
   
   
       34 . The stretch wrapping system of  claim 33 , wherein the first distance is less than the second distance.  
   
   
       35 . The stretch wrapping system of  claim 26 , wherein the conveyor is configured to receive a load from a pallet truck.  
   
   
       36 . The stretch wrapping system of  claim 35 , wherein the pallet truck includes forks configured to support a base of a pallet a first distance from the base surface, wherein the at least two conveyor elements extend a second distance above the base surface, and wherein the second distance is less than the first distance.  
   
   
       37 . The stretch wrapping system of  claim 26 , wherein the at least two conveyor elements are spaced to permit the passage of pallet truck forks between them.  
   
   
       38 . The stretch wrapping system of  claim 26 , wherein each conveying surface is formed by a plurality of rolling elements positioned between the side rails.  
   
   
       39 . The stretch wrapping system of  claim 38 , wherein the non-powered rollers are mounted on shafts connected to the rails.  
   
   
       40 . The stretch wrapping system of  claim 26 , wherein the pusher assembly includes an L-shaped pusher arm.  
   
   
       41 . The stretch wrapping system of  claim 40 , wherein the pusher arm is rotatable.  
   
   
       42 . The stretch wrapping system of  claim 40 , wherein the pusher arm is rotatable between an upright, vertical position and a lowered, horizontal position.  
   
   
       43 . The stretch wrapping system of  claim 40 , wherein the pusher assembly further includes a second pusher arm.  
   
   
       44 . The stretch wrapping system of  claim 40 , wherein the pusher arms are linked to move together.  
   
   
       45 . The stretch wrapping system of  claim 26 , wherein the means for providing relative rotation includes a rotatable arm.  
   
   
       46 . The stretch wrapping system of  claim 26 , wherein the low profile accumulation conveyor includes a load accumulation area, a load wrapping area, and a load exit area.  
   
   
       47 . The stretch wrapping system of  claim 46 , further comprising an exit pusher assembly for pushing the load from the load wrapping area to the load exit area on the at least two conveying surfaces.  
   
   
       48 . The stretch wrapping system of  claim 26 , wherein the base surface includes a base plate.  
   
   
       49 . The stretch wrapping system of  claim 48 , wherein the at least two conveyor elements are mounted on the base plate.  
   
   
       50 . The stretch wrapping system of  claim 26 , wherein the base surface is one of a floor and the ground.  
   
   
       51 . The stretch wrapping system of  claim 26 , wherein the base surface includes at least one rolling plate.  
   
   
       52 . The stretch wrapping system of  claim 51 , wherein the at least one rolling plate is positioned on a base plate.  
   
   
       53 . The stretch wrapping system of  claim 52 , wherein the at least two conveyor elements are mounted on the base plate.  
   
   
       54 . The stretch wrapping system of  claim 26 , wherein the low profile conveyor further includes third and fourth conveyor elements.  
   
   
       55 . The stretch wrapping system of  claim 54 , wherein first and second conveyor elements are arranged on an upstream side of the means for providing relative rotation and the third and fourth conveyor elements are arranged on a downstream side of the means for providing relative rotation.  
   
   
       56 . The stretch wrapping system of  claim 55 , wherein each of the third and fourth conveyor elements have a longitudinal axis, and wherein the third and fourth conveyor elements are positioned such that the longitudinal axis of the third conveyor element is parallel to the longitudinal axis of the fourth conveyor element.  
   
   
       57 . The stretch wrapping system of  claim 55 , wherein the means for providing relative rotation includes a turntable.  
   
   
       58 . The stretch wrapping system of  claim 56 , wherein the longitudinal axes of the first and second conveying elements are not parallel to the longitudinal axes of the third and fourth conveying elements.  
   
   
       59 . A method of wrapping a palletized load with packaging material, comprising: 
 placing a palletized load to be wrapped onto a low profile conveyor comprising at least two non-powered conveyor elements, each conveyor element having a longitudinal axis and including an inner side rail, an outer side rail, and a conveying surface formed by a plurality of rolling elements positioned between the side rails, wherein the longitudinal axis of one of the conveyor elements is parallel to the longitudinal axis of the other of the conveyor element, and a base surface positioned between the conveyor elements;    pushing the load with a powered pusher assembly to move the load on the conveying surfaces of the at least two conveyor elements; and    providing relative rotation between a packaging material dispenser and the load to wrap packaging material around sides of the loads.    
   
   
       60 . The method of  claim 59 , wherein pushing the load includes moving the load from a load accumulation area to a load wrapping area.  
   
   
       61 . The method of  claim 59 , wherein pushing the load includes moving the load from a load wrapping area to a load exit area.  
   
   
       62 . The method of  claim 59 , wherein the packaging material dispenser is mounted on a rotatable arm and wherein providing relative rotation includes rotating the rotatable arm.  
   
   
       63 . The method of  claim 59 , wherein providing relative rotation includes rotating a turntable supporting the load.  
   
   
       64 . A method of wrapping a palletized load with packaging material, comprising: 
 placing a first palletized load of a dual load carried by a pallet truck onto a low profile load conveyor comprising at least two non-powered conveyor elements, each conveyor element having a longitudinal axis and including an inner side rail, an outer side rail, and a conveying surface formed by a plurality of rolling elements positioned between the side rails, wherein the longitudinal axis of one of the conveyor elements is parallel to the longitudinal axis of the other of the conveyor elements, and a base surface positioned between said conveyor elements;    placing a second palletized load of the dual load carried by the pallet truck onto the low profile load accumulation conveyor;    pushing the first palletized load with a powered pusher assembly to move the first palletized load on the conveying surfaces into a wrapping area; and    providing relative rotation between a packaging material dispenser and the first palletized load to wrap packaging material around sides of the first palletized load.    
   
   
       65 . The method of  claim 64 , further comprising building a dual load on pallets carried on a pallet truck.  
   
   
       66 . The method of  claim 64 , further comprising pushing the wrapped first palletized load with a second powered pusher assembly to move the wrapped load on the conveying surfaces.  
   
   
       67 . The method of  claim 64 , further comprising, subsequent to wrapping the first palletized load, pushing the second palletized load with the powered pusher assembly to move the second palletized load on the conveying surfaces into a wrapping area.  
   
   
       68 . The method of  claim 64 , wherein placing the first palletized load of the dual load carried by the pallet truck includes driving the pallet truck onto the base surface and lowering forks of the pallet truck to position the first palletized load on the conveying surfaces.  
   
   
       69 . The method of  claim 68 , wherein driving onto the base surface includes guiding the forks of the pallet truck between the at least two conveyor elements.  
   
   
       70 . The method of  claim 69 , wherein guiding the forks of the pallet truck includes moving each fork between one of the at least two conveyor elements and a raised structure centered between the at least two conveyor elements.  
   
   
       71 . The method of  claim 68 , wherein placing the first palletized load of the dual load carried by the pallet truck further includes backing the pallet truck up to withdraw the forks from fork holes in the pallet supporting the first palletized load.  
   
   
       72 . The method of  claim 64 , wherein the packaging material dispenser is mounted on a rotatable arm and wherein providing relative rotation includes rotating the rotatable arm.  
   
   
       73 . The method of  claim 64 , wherein providing relative rotation includes rotating a rotatable turntable supporting the load.  
   
   
       74 . The method of  claim 73 , further comprising rotating the turntable to position the load to be moved onto an exit conveyor comprising at least two non-powered conveyor elements, each conveyor element having a longitudinal axis and including an inner side rail, an outer side rail, and a conveying surface formed by a plurality of rolling elements positioned between the side rails, wherein the longitudinal axis of one of the conveyor elements is parallel to the longitudinal axis of the other of the conveyor elements, and a base surface positioned between said conveyor elements.  
   
   
       75 . A low profile conveyor, comprising: 
 at least two conveyor elements, each conveyor element having a longitudinal axis and including an inner side rail, an outer side rail, and a conveying surface formed by a plurality of rolling elements positioned between the side rails, wherein the longitudinal axis of one of the conveyor elements is parallel to the longitudinal axis of the other of the conveyor elements;    a base surface positioned between the conveyor elements; and    a powered pusher assembly for moving the load on the conveying surfaces of the at least two conveyor elements.    
   
   
       76 . The low profile conveyor of  claim 14 , wherein pushing the wrapped load includes rotating a pusher arm from an upright position to a horizontal position.  
   
   
       77 . The low profile conveyor of  claim 63 , wherein pushing the load includes engaging a side of the load with a portion of a pusher assembly.  
   
   
       78 . A stretch wrapping system for wrapping palletized loads, comprising: 
 a dispenser for dispensing packaging material;    means for providing relative rotation between the dispenser and a load to be wrapped to wrap packaging material around the load;    a first low profile conveyor portion comprising first and second conveyor elements, each conveyor element having a longitudinal axis and including an inner side rail, an outer side rail, and a conveying surface formed by a plurality of rolling elements positioned between the side rails, wherein the longitudinal axis of the first conveyor element is parallel to the longitudinal axis of the second conveyor element, and a base surface positioned between the first and second conveyor elements;    a second low profile conveyor portion comprising third and fourth conveyor elements, each conveyor element having a longitudinal axis and including an inner side rail, an outer side rail, and a conveying surface formed by a plurality of rolling elements positioned between the side rails, wherein the longitudinal axis of the third conveyor element is parallel to the longitudinal axis of the fourth conveyor element, and a base surface positioned between the third and fourth conveyor elements; and    at least one powered pusher assembly for moving the load on the conveying surfaces.    
   
   
       79 . The stretch wrapping system of  claim 78 , wherein the conveyor elements are non-powered.  
   
   
       80 . The stretch wrapping system of  claim 78 , wherein the conveying surfaces of the each of the conveyor elements are between about 3.5 inches and 0.5 inches above the base surface.  
   
   
       81 . The stretch wrapping system of  claim 80 , wherein the conveying surfaces of each of the conveyor elements is approximately 1 inch above the base surface.  
   
   
       82 . The stretch wrapping system of  claim 78 , wherein each of the low profile conveyors further includes a guide element.  
   
   
       83 . The stretch wrapping system of  claim 82 , wherein each guide element includes a raised structure.  
   
   
       84 . The stretch wrapping system of  claim 78 , wherein each conveyor is configured to receive a load from a pallet truck.  
   
   
       85 . The stretch wrapping system of  claim 78 , wherein the powered pusher assembly includes an L-shaped arm.  
   
   
       86 . The stretch wrapping system of  claim 85 , wherein the pusher arm is rotatable.  
   
   
       87 . The stretch wrapping system of  claim 78 , further including a second powered pusher assembly.  
   
   
       88 . The stretch wrapping system of  claim 87 , wherein a first powered pusher assembly is adjacent the first low profile conveyor and a second powered pusher assembly is adjacent the second low profile conveyor.