U.S. patent application number 10/448334 was filed with the patent office on 2004-03-04 for wire coil winding apparatus and method.
Invention is credited to Farrar, Graham J., Peroni, Drew B..
Application Number | 20040040451 10/448334 |
Document ID | / |
Family ID | 31977459 |
Filed Date | 2004-03-04 |
United States Patent
Application |
20040040451 |
Kind Code |
A1 |
Peroni, Drew B. ; et
al. |
March 4, 2004 |
Wire coil winding apparatus and method
Abstract
Apparatus and method is provided for converting a long
indefinite length of wire from a supply bundle into a measured
length, tightly wound coil. The wire is driven from the supply by a
constant speed capstan to a winding station. A measured length of
wire is wrapped around a mandrel between a pair of flanges under
controlled tension conditions. After winding, a series of bands are
passed through the coil bore and respective ends of banding
material are twisted together and flattened against the coil
surface. The banded coil is ejected from the mandrel to a conveyor
or container.
Inventors: |
Peroni, Drew B.; (York,
PA) ; Farrar, Graham J.; (Wakefield, GB) |
Correspondence
Address: |
LAW OFFICE OF LEO ZUCKER
SUITE 480
50 MAIN STREET
WHITE PLAINS
NY
10606-1964
US
|
Family ID: |
31977459 |
Appl. No.: |
10/448334 |
Filed: |
May 29, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10448334 |
May 29, 2003 |
|
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10234752 |
Sep 4, 2002 |
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Current U.S.
Class: |
100/5 |
Current CPC
Class: |
B65B 13/28 20130101 |
Class at
Publication: |
100/005 |
International
Class: |
B65B 063/04 |
Claims
What is claimed is:
1. Apparatus for coil winding, comprising: (a) a supply of wire;
(b) a winding station for forming the wire into a coil having a
bore and an outer diameter; (c) means for driving the wire from the
supply to the winding station; (d) a banding supply for supplying a
length of banding material having a first end and a second end; (e)
means for passing the first end of the length of banding material
through the bore of the coil; and (f) means for securing the second
end to the first end of the length of banding material so as to
snugly band a portion of the coil.
2. The apparatus for coil winding described in claim 1, wherein the
winding station comprises a mandrel extending between a pair of
flanges and the means for passing the first end of banding material
through the bore of the coil comprises a banding material supply
device and a channel formed in the flanges and the mandrel, the
channel being inwardly open.
3. The apparatus for coil winding described in claim 2, further
comprising a bar positioned adjacent the winding station for
orienting the secured first and second ends of the length of
banding material close to a peripheral surface of the coil.
4. The apparatus for coil winding described in claim 1, further
comprising a ram operable for forcing a secured second end and
first end of the banding material into contact with an outer
diameter of the coil.
5. The apparatus for coil winding described in claim 1, further
comprising a sensor positioned adjacent the wire for detecting
whether the wire is present.
6. The apparatus for coil winding described in claim 1, further
comprising a detector for detecting whether the wire is operating
under excessive tension.
7. Apparatus for coil winding, comprising: (a) a wire supply
holder; (b) a winding station for forming a selected length of the
wire into a coil having a bore and an outer diameter, the winding
station comprising a pair of opposed flanges and a mandrel; (c)
means for driving the wire from the wire supply holder to the
winding station (d) a banding supply for supplying a length of
banding material having a first end and a second end; (e) the
flanges and mandrel being formed with a channel for passing the
first end of the length of banding through the bore of the coil;
and (f) a rotatable clamp for twisting the second end and the first
end of the length of banding material so as to snugly band the
coil.
8. The apparatus for coil winding described in claim 7, wherein the
channel in the flanges and mandrel is open in a direction facing
the coil.
9. The apparatus for coil winding described in claim 7, wherein the
banding material is a wire.
10. The apparatus for coil winding described in claim 7, further
comprising a ram operable for forcing the twisted second end and
first end into contact with an outer diameter of the coil.
11. The apparatus for coil winding described in claim 7, further
comprising a positionable guide mounted between the means for
driving the wire and the winding station.
12. The apparatus for coil winding described in claim 7, further
comprising means for applying a controlled tension to the wire.
13. The apparatus for coil winding described in claim 12, wherein
the means for applying a controlled tension to the wire comprises a
magnetic brake positioned for contacting the wire to apply tension
thereto.
14. The apparatus for coil winding described in claim 7, wherein
the means for driving the wire comprises a drive capstan operable
to drive the wire at a substantially constant linear speed.
15. The apparatus for coil winding described in claim 7, further
comprising means to drive the mandrel to apply tension to the
wire.
16. The apparatus for coil winding described in claim 15, wherein
the mandrel is configured to receive and grip a starting end of the
wire.
17. A method for winding a wire to form a coil, comprising the
steps of: (a) threading the wire along a path from a wire supply
holder to a winding station; (b) attaching a starting end of the
wire to a mandrel; (c) moving the length of wire along the path at
a substantially constant linear speed; (d) causing the mandrel to
rotate; (e) causing the wire to move in an axial direction relative
to the mandrel at a selected traversing speed; (f) stopping the
rotation and traversing at the completion of winding a
pre-determined length of wire to form a coil; (g) banding the coil
of wire in a plurality of places; and (h) ejecting the banded
coil.
18. The method for winding a wire as described in claim 17, wherein
the step of banding the coil of wire comprises passing a first end
of a length of banding material through a bore of the coil and
securing a second end to the first end.
19. The method for winding a wire as described in claim 17, wherein
the step of banding the coil of wire comprises passing a first end
of a length of banding material through a channel formed in the
mandrel and securing a second end to the first end.
20. The method for winding a wire as described in claim 17, further
comprising cutting an end of the wire and bending the end of wire
back to maintain the coil as wound.
21. The method for winding a wire as described in claim 17, wherein
the step of causing the mandrel to rotate comprises varying the
mandrel rotating speed so as to match the rotation of the mandrel
to the substantially constant linear speed of movement of the
length of wire.
22. The method for winding a wire as described in claim 17, wherein
the step of causing the mandrel to rotate further comprises causing
the mandrel to rotate slowly for a selected number of revolutions
and thereafter to rotate more quickly.
23. The method for winding a wire as described in claim 22, further
comprising causing the mandrel to rotate slowly during a period
when a quantity of wire on the mandrel approaches the
pre-determined length of wire and thereafter to stop.
24. The method for winding a wire as described in claim 17, wherein
the step of banding the coil of wire in a plurality of places
comprises banding the coil of wire in four places.
25. The method for winding a wire as described in claim 17, wherein
the step of causing the wire to move in an axial direction relative
to the mandrel further comprises adjusting the speed of the
relative movement in the axial direction in relation to the
rotation of the mandrel.
26. The method for winding a wire as described in claim 18, wherein
the step of securing comprises twisting the first and second ends
together and the method further comprises causing the twisted ends
into close contact with a peripheral surface of the coil.
27. The method for winding a wire as described in claim 26, wherein
the step of causing the twisted ends into close contact with a
peripheral surface of the coil comprises impacting the twisted ends
with a ram.
Description
[0001] This Invention is a Divisional of patent application Ser.
No. 10/234,752, filed Sep. 4, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of wire coil
winding and more particularly to apparatus and method for winding a
wire coil and automatically banding the wound coil.
BACKGROUND OF THE INVENTION
[0003] Wire is generally supplied in one of three types of package,
cut straight lengths in a box, wound on a spool or reel, and wound
into a coil without any supporting spool. The present invention
involves winding wire into a coil without any spool. Most wire,
although somewhat susceptible to retaining a shape into which it is
bent, will also exhibit a degree of resiliency and tend to partly
return to its pre-bend shape. Therefore, a wire that has been wound
into a coil shape will naturally tend to partly straighten, or
expand diameterally. In addition, wire is normally wound in coils
by the technique known as parallel winding, rather than cross
winding. Parallel winding has no significant transverse vector to
prevent the wound coil from spreading axially and losing its shape
integrity.
[0004] Both the diameteral expansion and the axial spread have been
historically controlled with banding that was applied by an
operator manually placing a wire or tape through the center and
around the periphery of the coil. If the banding material is a
wire, the operator performing the banding operation twisted the
ends together, trimmed the excess banding and flattened the twisted
wire against the coil periphery. If the banding material is tape,
coil security may require multiple wraps for each position. Since a
typical wire coil needs three or four circumferentially separated
bands for secure support, this manual operation involves a
significant amount of time and effort. The time involved both
prevents the machine devoted to coil winding from further
production during the banding operation and increases the labor
cost of making the wire coil.
[0005] Therefore, it is an object of the present invention to
provide a wire coiling apparatus and method capable of
automatically banding a wound coil.
[0006] It is an additional object of the present invention to
provide a wire coiling apparatus and method capable of
automatically banding a wound coil with a wire band and causing the
twisted ends of banding wire to be flattened against the coil.
[0007] These and other objects will become more apparent from the
description of the invention to follow.
SUMMARY OF THE INVENTION
[0008] A wire coil winding machine is provided with an automatic
coil banding mechanism. The wire is wound on a mandrel between a
pair of flanges to form a coil. The mandrel and flanges as a unit
have a number of channels cut into their mutual inner surface. At
the completion of winding a selected quantity of wire, the winding
stops. A series of bands are automatically driven through a channel
so as to encircle the coil from its bore to its circumference. The
ends of the bands are secured around the coil. The completed coil
is ejected from the mandrel and a second coil is started.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic elevation view of the coil winding
apparatus of the present invention.
[0010] FIGS. 2A-2D are a series of detailed sequential operational
diagrams of a coil banding section of the apparatus of the present
invention.
[0011] FIG. 3 is an enlarged cross sectional view of the coil
winding mandrel and flanges as taken in the direction of line 3-3
of FIG. 2A with a completed wire coil mounted thereon.
[0012] FIG. 4 is an enlarged perspective view of a wound and banded
wire coil as formed according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] According to the illustration of FIG. 1, the present
invention provides a machine 10 for winding a wire supplied in long
continuous lengths into compact, uniform coils. Although the
preferred embodiment of the invention is depicted in terms of
winding a wire product, i.e. an elongate metallic member, it is
recognized that the principles of the present invention can be
applied to other bendable materials, such as monofilament plastic
materials. A loosely formed wire supply bundle 14, formed of a long
length of wire 18, is mounted onto a wire supply holder 12 at the
entry end of coiling machine 10. For satisfactory operation, wire
supply bundle 14 must be formed with the wire in substantially
parallel, not tangled, loops. The present invention also
contemplates winding wire from a supply spool to a coil. The
possible supply spool may optionally be allowed to revolve around a
shaft with an applied drag or remain still while the wire is pulled
off axially, perhaps with the aid of a flyer, as is known. The wire
18 is threaded from supply holder 12 through a guide 20 that is
situated over the approximate center of supply holder 12, and then
past a break-out sensor 22 to be wrapped partly around pulley 24.
Wire 18 is held in intimate contact with the surface of pulley 24
by a captured belt (not shown) which is in contact with a portion
of the circumference of pulley 24. Wire 18 travels in the direction
indicated by several arrows along its length. Sensor 22 may be any
sort of known sensing device to confirm the presence of wire 18
adjacent thereto, or, if no wire 18 is detected, to stop operation
of apparatus 10 or signal an operator that a problem exists. The
entry edge of pulley 24 is vertically aligned with guide 20 and
sensor 22. Pulley 24 is rotatably mounted on a shaft and is able to
create an adjustable amount of running tension in wire 18 by the
application of a controllable drag, for example as created by a
magnetic brake 26. Alternate means for creating tension, for
example a mechanical brake, would also perform the basic function
required. However, the use of magnetic brake 26 permits adjustment
and control of its applied drag with electrical signal input from a
microprocessor such as PLC 68, according to the preferred
embodiment of the invention.
[0014] Wire 18 is then threaded in an elongated loop around a
dancer assembly including rotatably mounted sheave 30 and dancer
sheave 32 to pass through guide 38 and wound partly around drive
capstan 40. Sheave 30 and dancer sheave 32 each represent multiple
sheaves on a pair of common shafts, in the preferred embodiment.
Sheave 30 is mounted fixedly in a position so its top edge is
preferably in tangential contact with a horizontal line extending
from the top of tension pulley 24 to the center of guide 38. Dancer
sheave 32 is mounted so as to be able to move, e.g. upwardly, in
response to increased tension on wire 18 in the direction indicated
by arrow A. When wire 18 is running without tangles in the range of
normally applied supply tension, dancer sheave 32 is in its normal
state being held at or close to the bottom of its travel distance
by an applied force, in the preferred embodiment being caused by a
pneumatic cylinder (not shown). A detector 34 is positioned
adjacent dancer 32 to provide a warning signal or to shut down
machine 10 in case of a great increase in operating tension on wire
18. For example if supply bundle 14 becomes tangled or wire 18 is
snagged, dancer sheave 32 will be raised, due to the tension on
wire 18, to the position shown in dashed lines 32a, and detector 34
will be actuated.
[0015] Continuing with reference to FIG. 1, after passing through
guide 38, wire 18 is wrapped partly around drive capstan 40 which
is driven by a motor (not shown). Wire 18 is held in intimate
contact with drive capstan 40 by means of a captured belt (not
shown) which conforms to drive capstan 40 around approximately one
quarter of its circumference. Alternately, wire 18 may be wrapped
multiple times around drive capstan 40 for secure drive speed
control. Capstan 40 operates at a substantially constant rotational
speed to impart the force to drive wire 18 at a substantially
constant linear speed. A guide tube 42 is mounted along a line that
is vertically tangent to the exit edge of drive capstan 40 and
perpendicularly centered on an upper surface of cutter 46. Guide
tube 42, in the preferred embodiment, is formed with two partial
tubes that are telescopically extendable in the direction indicated
by arrow B. The upper portion of guide tube 42 is vertically
positionable as shown by arrow B to be close to capstan 40 during
operation of apparatus 10 and farther from capstan 40 for ease of
threading wire 18 therethrough. A device, e.g. a locking collar
(not shown), is provided to affix guide tube 42 at a selected
length. The lower end of guide tube 42 is fixedly mounted an
arbitrary distance above cutter 46.
[0016] Cutter 46 is formed, in the preferred embodiment, by an
upper and a lower guide plate, each having a vertical through hole
formed therein. Each through hole is aligned with the other through
hole during winding of a wire coil in machine 10 to allow wire 18
to pass freely. Alternate cutter designs may be employed within the
scope of the present invention. Wire 18 is moved by capstan 40 to
pass through telescoping guide tube 42 and through the aligned
upper and lower holes in cutter 46. The forward end of wire 18
ultimately moves to a winding station to pass in contact with guide
pulley 48 that is positioned beneath and aligned with the guide
holes in cutter 46. In the preferred embodiment, the leading end of
wire 18 is fed past guide pulley 48 and into a hole or slot in
mandrel 72 at the beginning of a winding cycle. Coil winding
proceeds at a relatively slow rotational speed for several
revolutions, e.g. four revolutions, until wire 18 is securely
engaged on mandrel 72, and then gradually accelerates to a
pre-selected constant linear running speed which is maintained for
the balance of the wind cycle. The running speed of wire 18 is
preferably a substantially fixed linear speed as controlled by
drive capstan 40. The rotation of coil 50 is driven at decreasing
rotational speed by a motor (not shown) that is operating in what
has been known as torque mode so as to match the fixed linear speed
of and provide drawing tension to wire 18.
[0017] Guide pulley 48 is maintained in a fixed position to control
wire 18 as it is wound into a coil 50 as described more fully
below. During the winding cycle in which coil 50 is formed, coil 50
is rotated in the direction indicated by arrow C, and coil 50 is
simultaneously moved axially in a direction into and out of the
plane of FIG. 1 to create a slow traverse parallel-wound coil.
"Parallel wound" is a term used to indicate that each loop of wire
18 in coil 50 is substantially perpendicular to the axis of coil 50
and substantially parallel to other wire loops in a wire layer. The
pitch of winding from a first to a subsequent adjacent wire loop on
the circumference of coil 50 is adjustable by changing the speed at
which coil 50 is caused to traverse (into and out of the plane of
FIG. 1) while the linear speed of wire 18 remains constant so as to
optimize productivity. The traverse movement of coil 50 is driven
by a separate drive motor connected to a linear actuator, for
example a drive screw mechanism.
[0018] Coil 50 is wound in the winding station on a mandrel 72
between two spaced apart flanges as will be described more fully
below. Mandrel 72 is rotated by a motor capable of variable speed
operation and having an encoder to signal the number of revolutions
run and its angular position. Coil 50 winding continues to rotate
until a pre-set value, representing a selected length of wire 18,
has been reached. A finished coil 50 is preferably similar in outer
diameter to the diameter of flanges 70a and 70b. At the completion
of the winding cycle, wire 18 and mandrel 72 gradually decelerate
and simultaneously stop operating. A banding supply station 54
supplies plural lengths of banding material 56, preferably a
banding wire, to place multiple bands perpendicularly from the bore
to the periphery of coil 50. After the application of one or more
bands, one of the guide plates of cutter 46 is caused to move, e.g.
by a pneumatic cylinder, in a direction perpendicular to the linear
direction of wire 18 to sever wire 18 in a scissor-like action
between the upper and lower guide holes. The plates of cutter 46
are returned to their normal position in which the guide holes are
aligned. Coil 50 is caused to rotate slowly for a portion of a
revolution in a direction opposite to that indicated by arrow C to
cause the cut end of wire 18 to engage bar 52 and be turned
backwards as compared to the direction in which coil 50 was wound.
In this manner, wire 18 is secured against unraveling by being
locked around a band of banding wire 56. Mandrel 72 and coil 50 are
indexed 900 to apply each successive band in the manner described
above until a selected number, e.g. four, bands are applied.
[0019] FIGS. 2A-2D illustrate sequential operational steps of
positioning coil 50 for banding, passing a banding material through
the bore of coil 50, bringing the ends of the banding material
together, and twisting the ends of banding material together. As
illustrated in sequential FIGS. 2A-2D, coil 50 is banded by wire
banding material 56, supplied by banding supply station 54 and
banding driver and cutter mechanism 58. FIG. 2A is a vertical plan
view of the winding mandrel 72/flange 70a combination and separable
flange 70b with a coil 50 formed therebetween at the end of the
winding cycle. Banding material 56 is moved from banding supply
station 54 toward coil 50. Depending on the characteristics of
banding wire 56, banding driver and cutter mechanism 58 is
optionally equipped with a wire straightening unit, as is known.
Wire banding material 56, for purposes of banding, is preferably
relatively annealed, as opposed to being hard and resilient, so as
to be compliant when twisted.
[0020] In FIG. 2A, flange 70a is seen to have a series of channels
76 that are separated circumferentially at angles of 90.degree.
from one another. As seen in FIGS. 2 and 3, channel 76 is wider at
the periphery of flange 70a than it is in the portion cut into
mandrel 72 and in the continued narrow channel passing outwardly
radially along flange 70b. Channels 76 are open toward the inner
surfaces of flanges 70a, 70b and mandrel 72. The mouth of channel
76a is relatively wide both in the circumferential and the axial
direction of flange 70a. Flange 70b is separable from mandrel 72
(see FIG. 3) by being moved in the direction indicated by arrow
H.
[0021] Returning to FIG. 2A, banding wire 56 is moved from supply
station 54 toward flange 70a. Banding wire 56 is cut to a desired
length by a cutting mechanism 58 as is known in the trade. An
alternate possibility is to supply precut lengths of banding wire
56. In FIG. 2B, banding wire 56 passes through flange 70a and
through channel 76 to exit from flange 70b. A pair of forks 74a and
74b, each formed with a "V" shaped open end that are oriented to
face one another, are then caused to move toward each other in the
direction indicated by arrows F to press the ends of banding wire
56 toward each other, forming a loop around one portion of coil 50.
Once the ends of banding wire 56 are brought together, shown in
FIG. 2C, jaws 62a and 62b are pivoted toward each other in the
direction of arrows E, to clamp onto the ends of banding wire 56,
and forks 74a and 74b are separated in the direction of arrows F to
rest in the positions shown in FIG. 2D. In FIG. 2D, jaws 62a and
62b are shown as being caused to rotate in the direction shown by
arrows G while maintaining pressure to grip the ends of banding
wire 56 so as to twist the ends of banding wire 56 together. Jaws
62a and 62b may optionally be rotated either clockwise or
counterclockwise. After a predetermined number of twists have been
imparted to the ends of banding wire 56, e.g. 8-12 turns, jaws 62a
and 62b separate. Jaws 62a and 62b are formed with a pressure
contact area (not shown), and the number of turns applied by jaws
62a, 62b is determined to be sufficient to securely bind coil 50
and cause the portion of banding wire 56 distal from coil 50 to
break off. Jaws 62a and 62b open, and coil 50 is rotated 900 to
position another set of channels for the insertion and securing of
banding wire 56.
[0022] The forming of wire bands as described above results in a
twisted wire end protruding radially outwardly from coil 50 at each
band position, i.e. four locations. In order to flatten the twisted
wire ends against the peripheral surface of coil 50, bar 52 (see
FIG. 1) is located close to the circumference of finished coil 50.
Coil 50 rotates between sequential banding operations, causing the
twisted ends of banding wire 56 to be bent toward the
circumferential surface of coil 50. Lastly, ram 66 is advanced
rapidly in the direction of arrow D to impact the twisted ends. Ram
66 is shaped substantially to match the contour of the periphery of
coil 50. This flattening operation is repeated for each of the
plural banding wires. Ram 66 is actuated by a pneumatic cylinder or
other driver.
[0023] FIG. 3 provides an enlarged, detailed cross sectional view
of flange 70a mandrel 72 and flange 70b with completed coil 50 in
position therebetween. Flanges 70a and 70b surround coil 50, and
banding wire 56 (shown as a dashed line) passing through channel
76a proceeds across the mandrel portion to exit through flange 70b.
At the completion of winding and banding coil 50, flange 70b
separates from the fixed assembly of flange 70a and mandrel 72, and
an ejector (not shown) discharges coil 50 from mandrel 72 onto a
receiving conveyor or into a container.
[0024] FIG. 4 illustrates coil 50 in completed wound and banded
form with four bands 56 individually wrapped through the bore and
around the periphery of coil 50. A typical set of dimensions for
completed coil 50 is that bore diameter d equals about 4.1 cm
(1.625 inch), outer diameter D equals about 13.6 cm (5.375 inch),
and traverse width W equals about 4.6 cm (1.812 inch). Coil size is
dependent upon the ultimate use to which coil 50 is put.
[0025] Coiling machine 10 (FIG. 1) is operationally controlled by
microprocessor 68 connected thereto. Microprocessor 68 is capable
of installing a previously recorded program or accepting
operator-set parameters to automatically control the coil winding
process of machine 10. Each parameter is represented by a counter
and display on a screen (depicted as circles on the screen of
microprocessor 68), with controls set to selected values by use of
a touch screen or a keyboard. Relevant parameters, according to the
preferred embodiment, include wire linear speed, mandrel traverse
speed, wire diameter, number of mandrel 72 turns at slow speed
before accelerating to running speed, magnetic brake 26 force to
instill tension, mandrel 72 drive torque, total length of wire 18
on coil 50 before stopping winding, length of banding wire 56,
number of banding wire 56 twists and number of ram 66 impacts per
wire banding. Microprocessor 68 receives signals from sensor 22 as
to the presence of wire 18 and from detector 34 as to the position
of dancer 32 and of potentially excessive tension in wire 18, as
well as operational information such as the linear running speed
and quantity wound of wire 18 and the number of coils 50 completed
in the production lot. Microprocessor 68 is adapted to save the
operating parameters for a complete program in an internal memory
or to record to a disc for future use. Alternately, the parameters
comprising the operating program may be saved to a tape or disc
memory device.
[0026] Therefore, the sequence of operations for automatic coil
winding according to the preferred embodiment of the invention is
as follows, referring to FIG. 1 for reference. An operator places a
wire supply package 14 on wire supply holder and threads the wire
18 through guide 20, past wire presence sensor 22 and around pulley
24 with magnetic brake 26. Wire 18 is further threaded around
sheave 30 and dancer sheave 32 which is monitored by detector 34 to
signal the operator and/or shut down operations in the event of
excessive tension. Wire 18 next passes through guide 38 and around
drive capstan 40, through telescopic tube 42, through cutter plates
46 and around pulley 48 to mandrel 72. The operator either manually
enters values for winding control on microprocessor 68 or inputs a
pre-recorded control program. Wire 18 is fed into a slot in mandrel
72, and mandrel 72 slowly rotates as it slowly traverses axially.
At the completion of several rotations at slow speed, mandrel 72
begins to rotate faster as the traverse similarly moves axially
faster to maintain a constant ratio of mandrel revolutions to
traverse motion. Mandrel 72 operates during the beginning of the
winding cycle at a full rotational speed that decreases as the
diameter of coil 50 increases so as to keep the linear speed of
wire 18 constant. When the length of wire 18 on coil 50 approaches
its pre-set maximum quantity, mandrel 72 begins to slow and then
stops at the pre-set quantity. Mandrel 72 is rotated to a position
where a first one of several channels 76 is positioned in line with
banding wire 56 coming from banding wire supply 54. A length of
banding wire 56 is moved to pass through channel 76 from a first to
a second flange adjacent mandrel 72, through the bore of coil 50.
The two ends of banding wire 56 are brought together by a pair of
forks 74a, 74b (see FIGS. 2A-2D) and grasped by jaws 62a, 62b as
forks 74a, 74b retract. Jaws 62a, 62b rotate to twist the ends of
the banding wire together and clip the excess length therefrom.
Jaws 62a, 62b open, and mandrel 72 rotates to the next sequential
banding position, for example 90.degree. farther, where the banding
process is repeated. Cutter 46 cuts wire 18 between application of
banding wires, and the cut end of wire 18 is turned back on itself
and flattened by contact with bar 52 as mandrel 72 is rotated
backwards for this purpose. In rotating to a next banding position,
mandrel 72 causes each twisted wire end to pass under bar 52 to
bend the twisted ends close to the periphery of coil 50. When a set
of twisted ends is positioned appropriately, ram 66 is driven
forward to flatten the twisted ends into a relatively safe
placement against coil 50. After all banding is completed and the
twisted ends are flattened into the surface of coil 50, flange 70b
moves away from mandrel 72 and a discharge ram is actuated to eject
completed coil 50. Upon a signal from a sensor that coil 50 has
moved out of the winding mechanism, flange 70b, moves back into
contact with mandrel 72 and the process is repeated.
[0027] While the present invention is described with respect to
specific embodiments thereof, it is recognized that various
modifications and variations may be made without departing from the
scope and spirit of the invention, which is more clearly and
precisely defined by reference to the claims appended hereto.
* * * * *