U.S. patent application number 14/737237 was filed with the patent office on 2015-12-17 for system and method for securing free end of wound cable.
This patent application is currently assigned to WINDAK INC.. The applicant listed for this patent is WINDAK INC.. Invention is credited to Daniel L. Shelander.
Application Number | 20150360800 14/737237 |
Document ID | / |
Family ID | 54834362 |
Filed Date | 2015-12-17 |
United States Patent
Application |
20150360800 |
Kind Code |
A1 |
Shelander; Daniel L. |
December 17, 2015 |
SYSTEM AND METHOD FOR SECURING FREE END OF WOUND CABLE
Abstract
A system for securing a free end of a cable wound on a spool
includes a spooling machine having at least one spooling head for
winding a length of the cable onto the spool and a stretch wrap
applicator for securing the free end of the cable on the spool with
stretch wrap that is pinched between the free end of the cable and
the outermost windings of the cable wound on the spool. A stretch
wrap applicator for a spooling machine having at least one spooling
head includes a housing, a roll of stretch wrap disposed within the
housing and a pulling clamp for gripping and pulling a starting end
of the stretch wrap so as to position the stretch wrap between a
spool of wound cable having outermost windings and a free end of
the cable wound on the spool. A method for securing the free end of
a cable wound on a spool includes providing the spooling machine
and the stretch wrap applicator, moving the pulling clamp from an
initial position around a free end of the cable, gripping a
starting end of the stretch wrap, moving the pulling clamp and the
stretch wrap back to the initial position with the stretch wrap
disposed between the free end and the outermost windings of the
cable and moving the pulling clamp in a downward direction so as to
pinch the stretch wrap within a nip defined between the outermost
windings and the free end of the cable.
Inventors: |
Shelander; Daniel L.;
(Hickory, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WINDAK INC. |
Hickory |
NC |
US |
|
|
Assignee: |
WINDAK INC.
Hickory
NC
|
Family ID: |
54834362 |
Appl. No.: |
14/737237 |
Filed: |
June 11, 2015 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62011013 |
Jun 11, 2014 |
|
|
|
Current U.S.
Class: |
53/399 ;
53/556 |
Current CPC
Class: |
B65B 2210/16 20130101;
B65B 11/025 20130101; B65B 25/24 20130101; B65B 61/06 20130101;
B65H 75/285 20130101; B65B 11/04 20130101 |
International
Class: |
B65B 53/00 20060101
B65B053/00; B65B 11/54 20060101 B65B011/54; B65B 61/06 20060101
B65B061/06; B65B 45/00 20060101 B65B045/00; B65B 11/02 20060101
B65B011/02; B65B 41/12 20060101 B65B041/12 |
Claims
1. A system, comprising: a spooling machine having at least one
spooling head for winding a length of an elongate, flexible
component onto a spool; and a stretch wrap applicator configured
for and operable for securing a free end of the elongate, flexible
component on the spool with stretch wrap; wherein the stretch wrap
is pinched between the free end and outermost windings of the
elongate flexible component wound on the spool.
2. The system of claim 1, wherein the spooling machine comprises
two spooling heads and wherein the stretch wrap applicator is
mounted on the spooling machine for transverse movement relative to
the spooling heads.
3. The system of claim 2, wherein the spooling machine further
comprises a rail and a drive mechanism and wherein the stretch wrap
applicator is operably coupled with the drive mechanism for
transverse movement along the rail relative to the two spooling
heads.
4. The system of claim 2, wherein the two spooling heads of the
spooling machine are positioned at transversely spaced-apart
locations along the rail and wherein the stretch wrap applicator is
operable for transverse movement between the spooling heads.
5. The system of claim 1, wherein the stretch wrap applicator
comprises a pulling clamp configured for and operable for being
moved from an initial position around the free end of the elongate,
flexible component wound on the spool and into engagement with a
starting end of the stretch wrap.
6. The system of claim 5, wherein the pulling clamp is affixed to
the starting end of the stretch wrap sufficiently to unwrap the
stretch wrap off a roll of the stretch wrap.
7. The system of claim 5, wherein the pulling clamp is further
configured for and operable for moving back to the initial position
while gripping the starting end of the stretch wrap such that the
stretch wrap is disposed between the free end of the elongate,
flexible component and the remaining length of the elongate,
flexible component wound on the spool.
8. The system of claim 7, wherein the stretch wrap is disposed
between the free end of the elongate, flexible component and
outermost windings of the elongate, flexible component wound on the
spool.
9. The system of claim 7, wherein the pulling clamp is further
configured for and operable for moving downwardly relative to the
elongate, flexible component wound on the spool so that the stretch
wrap is pinched within a nip defined between the outermost windings
of the elongate, flexible component and the free end of the
elongate, flexible component.
10. The system of claim 9, wherein the pulling clamp is mounted on
an angled rail and is moved downwardly along the angled rail such
that the pulling clamp and the starting end of the stretch wrap are
moved in a generally tangential direction relative to a periphery
of the elongate, flexible component wound on the spool.
11. A stretch wrap applicator for a spooling machine having at
least one spooling head, the stretch wrap applicator comprising: a
housing; a roll of stretch wrap disposed within the housing; and a
pulling clamp configured for and operable for gripping and pulling
a starting end of the roll of stretch wrap so as to position the
stretch wrap between a spool of wound cable having outermost
windings and a free end of the cable wound on the spool.
12. The stretch wrap applicator of claim 11, wherein the stretch
wrap is pinched within a nip defined by the outermost windings of
the cable wound on the spool and the free end of the cable.
13. The stretch wrap applicator of claim 11, wherein the pulling
clamp is further configured for and operable for moving downwardly
relative to the spool of wound cable so as to dispose the stretch
wrap between the outermost windings of the cable wound on the spool
and the free end of the cable.
14. The stretch wrap applicator of claim 13, wherein the pulling
clamp is mounted on an angled rail that is movably attached to the
housing with a predetermined angle such that the pulling clamp and
a starting end of the stretch wrap are moved in a generally
tangential direction relative to an outer periphery of the cable
wound on the spool.
15. The stretch wrap applicator of claim 14, wherein the pulling
clamp is further configured for and operable for releasing the
starting end of the stretch wrap in contact with at least a portion
of the outermost windings of the cable wound on the spool so that
the stretch wrap disposed between the outermost windings of the
cable and the free end of the cable is wrapped around the spool as
the remaining length of the cable is wound onto the spool.
16. A method for securing the free end of an elongate, flexible
component wound onto a spool, the method comprising: providing a
spooling machine having at least one spooling head for winding a
length of the elongate, flexible component onto the spool;
providing a stretch wrap applicator operably coupled with the at
least one spooling head for applying stretch wrap to the elongate,
flexible component wound on the spool, the stretch wrap applicator
comprising a pulling clamp and a length of the stretch wrap; moving
the pulling clamp from an initial position around a free end of the
elongate, flexible component wound on the spool; gripping a
starting end of the stretch wrap with the pulling clamp; moving the
pulling clamp and the starting end of the stretch wrap back to the
initial position with the stretch wrap disposed between the free
end of the elongate, flexible component and outermost windings of
the elongate, flexible component; moving the pulling clamp in a
downward direction so as to pinch the stretch wrap within a nip
defined between the outermost windings of the elongate, flexible
component and the free end of the elongate, flexible component; and
cutting the free end of the elongate, flexible component and
wrapping the stretch wrap around the outermost windings of the
elongate, flexible component until the free end of the elongate,
flexible component is secured by the stretch wrap.
17. The method of claim 16, wherein the spooling machine comprises
two spooling heads and a transverse rail and wherein the stretch
wrap applicator is configured for and operable for moving in a
transverse direction along the rail relative to the spooling
heads.
18. The method of claim 16, wherein the stretch wrap applicator is
configured for and operable for moving between a first spooling
head of the spooling machine and a second spooling head of the
spooling machine subsequent to securing the free end of the
elongate, flexible component wound on a spool of the first spooling
head.
19. The method of claim 16, wherein moving the pulling clamp in a
downward direction comprises mounting the pulling clamp on an
angled rail that is movably attached to the housing with a
predetermined angle such that the pulling clamp and a starting end
of the stretch wrap are moved in a generally tangential direction
relative to an outer periphery of the elongate, flexible component
wound on the spool.
20. The method of claim 16, further comprising releasing the
starting end of the stretch wrap in contact with at least a portion
of the outermost windings of the elongate, flexible component wound
on the spool so that the stretch wrap disposed between the
outermost windings of the elongate, flexible component and the free
end of the elongate, flexible component is wrapped around the spool
as the remaining length of the elongate, flexible component is
wound onto the spool.
Description
CROSS-REFERENCE To RELATED APPLICATION
[0001] This application claims the benefit of priority to U.S.
Provisional Patent Application No. 62/011,013 filed on Jun. 11,
2014, the entire disclosure of which is incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to systems,
apparatus and methods for securing the free end of wound cable.
More particularly, the invention is a system and method for
securing the free end of a length of an elongate, flexible cable
that is wound onto a spool by a spooling machine. The free end of
the cable is secured using stretch wrap that is automatically
applied to a spool of wound cable as the cable is being cut so that
the leading end of the stretch wrap is nipped between the spool of
wound cable and the free end of the cable. In an exemplary
embodiment, the stretch wrap system is mounted horizontally and
movable in a transverse direction to service at least two cable
spooling stations on a spooling machine.
BACKGROUND OF THE INVENTION
[0003] It is common practice for lengths of elongate, flexible
components, such as strands of wire, tubing or cable to be wound
onto a spool. Oftentimes, the free end of the wound cable is
retained on the spool by a relatively thin layer of stretch wrap
that is wrapped around the spool after the desired length of cable
has been wound onto the spool. Typically, the free end of the cable
is temporarily held in place and a rotary arm is moved around a
stationary spooling head to wrap the stretch wrap onto the spool of
wound cable. The stretch-wrapped spool of wound cable is then
removed from the spooling head of the spooling machine and
transferred into a container or onto a pallet for transporting a
plurality of the cable spools to an end user.
[0004] Spooling machines are known for automatically winding a
length of elongate, flexible cable, for example coaxial cable or
fiber optic cable, onto a spool and for automatically applying
stretch wrap to the spool of wound cable. A spooling machine
including fully automatic dual take-ups for on-line or off-line
packaging of cable products is available from the Hall Industries
division of the MGS Group having its corporate offices located in
Rome, New York, USA. The MGS/Hall spooling machine includes two
winding stations for winding a length of cable onto a spool and for
applying a relatively thin layer of stretch wrap to the spool of
wound cable to secure the free end of the cable onto the spool.
Each winding station has a spooling head that is provided with a
positive automatic stretch wrap applicator. The stretch wrap
applicator operates to apply the stretch wrap to the spool of wound
cable so that the starting end of the stretch wrap is positively
pinched under the free end of the cable just prior to the
conclusion of the winding cycle.
[0005] The automatic stretch wrap applicator provided at each
winding station of the MGS/Hall spooling machine includes two
clamps and a push-down roller. The first stretch wrap clamp
operates to pull the starting end of the stretch wrap from a
stretch wrap roll to a position that is relatively close to the
spool of wound cable. The push-down roller next operates to move
the stretch wrap to the opposite side of the wound cable. The
second stretch wrap clamp then operates to grab the stretch wrap
from the opposite side and to pull the stretch wrap back across the
spool of wound cable. However, a number of disadvantages,
deficiencies and problems are associated with the automatic stretch
wrap applicator of the MGS/Hall spooling machine. The MGS/Hall
stretch wrap applicator requires an excessive number of separate
components, which results in high cost and reduced reliability of
the applicator. In addition, the MGS/Hall stretch wrap applicator
does not pull the stretch wrap between layers of the wound cable.
Therefore, the relatively thin layer of stretch wrap can slip on a
wound cable having an excessively smooth or slick jacket, and as a
result, not be pulled around the spool of wound cable. As
previously mentioned, the MGS/Hall spooling machine utilizes two
vertically oriented spooling heads and requires a separate stretch
wrap applicator for each spooling head. Since the spooling heads
are oriented vertically, the free end of the cable can bend
downwardly under the influence of gravity relative to the feed
direction of the stretch wrap. Thus, the free end of the cable can
extend outwardly from beneath the stretch wrap and potentially snag
causing premature removal of the stretch wrap. Furthermore, the use
of a separate stretch wrap applicator for each of the two spooling
heads unnecessarily duplicates components of the spooling machine
and increases acquisition, maintenance and operating costs.
SUMMARY OF THE INVENTION
[0006] The present invention is a system and method for winding a
length of cable onto a spool and automatically applying stretch
wrap onto the spool of wound cable to secure the free end of the
cable on the spool. More particularly, the invention is a stretch
wrap applicator for a spooling machine having two spooling heads
and a method for applying stretch wrap onto a spool of wound cable
at each spooling head to secure the free end of the cable on the
spool.
[0007] In one aspect, the invention is embodied by a system
including a spooling machine having at least one spooling head for
winding a length of an elongate, flexible component onto a spool
and a stretch wrap applicator configured for and operable for
securing a free end of the elongate, flexible component on the
spool with stretch wrap. The stretch wrap applicator pinches the
stretch wrap between the free end and outermost windings of the
elongate flexible component wound on the spool. In one embodiment,
the spooling machine has two spooling heads and the stretch wrap
applicator is mounted on the spooling machine for transverse
movement relative to the spooling heads. The spooling machine may
have a rail and a drive mechanism and the stretch wrap applicator
may be operably coupled with the drive mechanism for transverse
movement along the rail relative to the two spooling heads. The two
spooling heads of the spooling machine may be positioned at
transversely spaced-apart locations along the rail and the stretch
wrap applicator may be operable for transverse movement between the
spooling heads. In another embodiment, the stretch wrap applicator
includes a pulling clamp configured for and operable for being
moved from an initial position around the free end of the elongate,
flexible component wound on the spool and into engagement with a
starting end of the stretch wrap. The pulling clamp is further
configured for and operable for moving back to the initial position
while gripping the starting end of the stretch wrap such that the
stretch wrap is disposed between the free end and the outermost
windings of the elongate, flexible component wound on the spool.
The pulling clamp is further configured for and operable for moving
downwardly relative to the elongate, flexible component wound on
the spool so that the stretch wrap is pinched within a nip defined
between the outermost windings of the elongate, flexible component
and the free end of the elongate, flexible component.
[0008] In another aspect, the invention is embodied by a stretch
wrap applicator for a spooling machine having at least one spooling
head. The stretch wrap applicator includes a housing, a roll of
stretch wrap disposed within the housing and a pulling clamp
configured for and operable for gripping and pulling a starting end
of the roll of stretch wrap so as to position the stretch wrap
between a spool of wound cable having outermost windings and a free
end of the cable wound on the spool. The stretch wrap is pinched
within a nip defined by the outermost windings of the cable wound
on the spool and the free end of the cable. The pulling clamp is
further configured for and operable for moving downwardly relative
to the spool of wound cable so as to dispose the stretch wrap
between the outermost windings of the cable wound on the spool and
the free end of the cable. In one embodiment, the pulling clamp is
mounted on an angled rail that is movably attached to the housing
with a predetermined angle such that the pulling clamp and a
starting end of the stretch wrap are moved in a generally
tangential direction relative to an outer periphery of the cable
wound on the spool. The pulling clamp is further configured for and
operable for releasing the starting end of the stretch wrap in
contact with at least a portion of the outermost windings of the
cable wound on the spool so that the stretch wrap disposed between
the outermost windings of the cable and the free end of the cable
is wrapped around the spool as the remaining length of the cable is
wound onto the spool.
[0009] In yet another aspect, the invention is embodied by a method
for securing the free end of an elongate, flexible component wound
onto a spool. The method includes providing a spooling machine
having at least one spooling head for winding a length of the
elongate, flexible component onto the spool and providing a stretch
wrap applicator operably coupled with the at least one spooling
head for applying stretch wrap to the elongate, flexible component
wound on the spool. The stretch wrap applicator includes a pulling
clamp and a length of the stretch wrap. The method further includes
moving the pulling clamp from an initial position around a free end
of the elongate, flexible component wound on the spool. The method
further includes gripping a starting end of the stretch wrap with
the pulling clamp. The method further includes moving the pulling
clamp and the starting end of the stretch wrap back to the initial
position with the stretch wrap disposed between the free end of the
elongate, flexible component and outermost windings of the
elongate, flexible component. The method further includes moving
the pulling clamp in a downward direction so as to pinch the
stretch wrap within a nip defined between the outermost windings of
the elongate, flexible component and the free end of the elongate,
flexible component. The method further includes cutting the free
end of the elongate, flexible component and wrapping the stretch
wrap around the outermost windings of the elongate, flexible
component until the free end of the elongate, flexible component is
secured by the stretch wrap. In one embodiment, the spooling
machine includes two spooling head and a transverse rail and the
stretch wrap applicator is configured for and operable for moving
in a transverse direction along the rail relative to the spooling
heads. The stretch wrap applicator moves between a first spooling
head of the spooling machine and a second spooling head of the
spooling machine subsequent to securing the free end of the
elongate, flexible component wound on a spool of the first spooling
head. In another embodiment, the pulling clamp is mounted on an
angled rail that is movably attached to the housing with a
predetermined angle such that the pulling clamp and a starting end
of the stretch wrap are moved in a generally tangential direction
relative to an outer periphery of the cable wound on the spool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a front perspective view of a stretch wrap
applicator for a spooling machine having two spooling heads that is
operable for automatically applying stretch wrap to a spool of
wound cable according to an exemplary embodiment of the
invention.
[0011] FIG. 2 is a rear perspective view illustrating the stretch
wrap applicator of FIG. 1 moving transversely relative to the
spooling heads to locate the stretch wrap applicator adjacent to
one of the spooling heads having a length of cable wound on a
spool.
[0012] FIG. 3 is a rear perspective view illustrating the stretch
wrap applicator of FIG. 1 moving transversely relative to the one
of the spooling heads to locate the stretch wrap applicator in line
with the free end of the wound cable.
[0013] FIG. 4 is a rear perspective view illustrating the stretch
wrap applicator of FIG. 1 moving the pulling clamp from an initial
position around the free end of the wound cable and into engagement
with the starting end of the stretch wrap.
[0014] FIG. 5 is a detailed rear perspective view showing the
pulling clamp of the stretch wrap applicator of FIG. 1 in gripping
engagement with the starting end of the stretch wrap.
[0015] FIG. 6 is a rear perspective view illustrating the pulling
clamp of the stretch wrap applicator of FIG. 1 being moved back to
the initial position such that the stretch wrap is disposed between
the spool and the free end of the wound cable.
[0016] FIG. 7A is a front perspective view illustrating the pulling
clamp of the stretch wrap applicator of FIG. 1 being moved
downwardly relative to the spool of wound cable such that the
stretch wrap is pinched within a nip defined by the outermost
windings of the cable and the free end of the wound cable.
[0017] FIG. 7B is a rear perspective view corresponding to the
front perspective view of FIG. 7A.
[0018] FIG. 8 is a front perspective view illustrating the puling
clamp of the stretch wrap applicator of FIG. 1 releasing the
starting end of the stretch wrap such that the stretch wrap will be
wrapped around the spool of wound cable by the free end of the
cable being wound onto the spool.
[0019] FIG. 9 is a rear perspective view illustrating the stretch
wrap applicator of FIG. 1 cutting the free end of the cable and
then subsequently winding the free end of the cable onto the spool
beneath the stretch wrap as the stretch wrap is wrapped around the
spool of wound cable.
[0020] FIG. 10 is a rear perspective view illustrating the stretch
wrap applicator of FIG. 1 moving transversely relative to the
spooling head of the spooling machine to thereby wrap the spool of
wound cable with the stretch wrap entirely from one outer flange to
the other outer flange.
[0021] FIG. 11 is a rear perspective view illustrating the spool of
wound cable wrapped with the stretch wrap transversely between one
outer flange and the other outer flange.
[0022] FIG. 12 is a rear perspective view illustrating the stretch
wrap applicator of FIG. 1 moving the stretch wrap cutter into a
cutting position relative to the finishing end of the stretch
wrap.
[0023] FIG. 13 is a rear perspective view showing the finishing end
of the stretch wrap being cut by the stretch wrap cutter of the
stretch wrap applicator of FIG. 1 and subsequently being wrapped
around the spool of wound cable to thereby secure the free end of
the wound cable so that the finished spool may be removed from the
spooling machine.
[0024] FIG. 14 is a rear perspective view illustrating the stretch
wrap applicator of FIG. 1 moving transversely relative to the two
spooling heads of the spooling machine to locate the stretch wrap
applicator adjacent to the other one of the spooling heads having a
length of cable wound on a spool.
[0025] FIG. 15 is a perspective view of a stretch wrap applicator
for applying stretch wrap to a coil of a desired length of cable
wound onto a spool according to another exemplary embodiment of the
present invention.
[0026] FIG. 16 is a perspective view showing the coil engaged by a
pair of side grippers of the stretch wrap applicator of FIG.
15.
[0027] FIG. 17 is a perspective view showing the free end of the
cable engaged by a cable end holder of the stretch wrap applicator
of FIG. 15.
[0028] FIGS. 18-23 are perspective views illustrating the stretch
wrap sequence for applying stretch wrap to the coil of wound cable
using the stretch wrap applicator of FIG. 15.
[0029] FIGS. 24-26 are perspective views illustrating the coil of
wound cable wrapped with stretch wrap moving from the stretch wrap
applicator of FIG. 15 to a driven conveyor system for delivering
the stretch wrapped coil to a container or a pallet for storage and
transport.
DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION
[0030] Referring now to the accompanying drawings, in which like
reference characters in the drawing figures refer to the same or
similar parts, a spooling machine, indicated generally at 10,
having two spooling heads, each indicated generally at 20 with the
corresponding winder not depicted for purposes of clarity, and a
stretch wrap applicator, indicated generally at 30, is shown in
FIGS. 1-14. The single stretch wrap applicator 30 is configured for
and operable to secure a free end 22 of a length of cable 24 wound
onto a spool 26 by wrapping the spool of wound cable with stretch
wrap 40 (see e.g., FIGS. 8-13). In the exemplary embodiments shown
and described herein, the stretch wrap applicator 30 is movable
transversely relative to the two spooling heads 20 of the spooling
machine 10 so that the single stretch wrap applicator is configured
for and operable to service both spooling heads. However, as will
be readily appreciated by those skilled in the art, if desired each
spooling head 20 of the spooling machine 10 may be provided with a
separate stretch wrap applicator 30 configured for and operative to
secure the free end 22 of a length of cable 24 wound onto a spool
26 at each spooling head. Furthermore, the spooling machine 10,
including the stretch wrap applicator 30 may be configured for use
with any elongate, flexible component, including without limitation
wire, tubing or cable, to form a spool of the wound component, and
to thereafter, wrap stretch wrap around the spool of the wound
component to secure the free end of the elongate, flexible
component on the spool. In preferred embodiments, the elongate,
flexible component is a cable, such as coaxial cable or fiber optic
cable. Those of ordinary skill will readily understand and
appreciate that the spooling machine 10 and the stretch wrap
applicator 30 may be used alone or in combination with one another
in various other applications without departing from the scope of
the invention, as broadly interpreted in light of this written
description. For purposes of illustration only, the spooling
machine 10 including the spooling heads 20 and the stretch wrap
applicator 30 are shown and described herein for use with reference
to coaxial or fiber optic cable 24 of the type commonly utilized by
an end user in communications applications.
[0031] FIG. 1 shows a spooling machine 10 including two spooling
heads 20 and a stretch wrap applicator 30 mounted for transverse
movement on the spooling machine relative to the spooling heads. As
shown, the spooling machine 10 comprises a transversely (i.e.,
generally horizontal) extending rail 12 and a drive mechanism 14,
such as a belt or chain driven by one or more rotating gears,
pulleys or the like, configured for and operable for moving the
stretch wrap applicator 30 along the rail transversely in a
generally horizontal direction relative to the spools 26 of the
spooling heads 20.
[0032] FIG. 2 illustrates the stretch wrap applicator 30 being
moved transversely relative to the spooling heads 20 of the
spooling machine 10 to locate the stretch wrap applicator adjacent
to one of the spooling heads on which a length of the cable 24 is
being wound onto a spool 26 between a pair of outer flanges 28. The
opposing arrows depicted in certain of the drawing figures indicate
the generally horizontal direction of movement of the stretch wrap
applicator 30 relative to the spooling heads 20 of the spooling
machine 10.
[0033] FIG. 3 illustrates the stretch wrap applicator 30 moved
transversely relative to the spooling heads 20 of the spooling
machine 10 so as to position the stretch wrap applicator in line
with the free end 22 of the cable 24 being wound onto the spool 26
between the outer flanges 28.
[0034] FIG. 4 illustrates a pulling clamp 32 of the stretch wrap
applicator 30 moved from an initial position shown in FIG. 3 around
the free end 22 of the cable 24 being wound onto the spool 26. The
pulling clamp 32 is moved from the initial position into engagement
with the starting end 42 of a roll of the stretch wrap 40 housed
within an interior of a housing 34 of the stretch wrap applicator
30. The pulling clamp 32 may be affixed to the starting end 42 of
the stretch wrap 40 in any manner suitable for gripping the
starting end sufficiently to unwrap the stretch wrap off the roll
of stretch wrap, as will be described in greater detail
hereinafter.
[0035] FIG. 5 is a detailed view showing the pulling clamp 32
disposed around the free end 22 of the cable 24 and in gripping
engagement with the starting end 42 of the stretch wrap 40.
[0036] FIG. 6 illustrates the pulling clamp 32 of the stretch wrap
applicator 30 moved back to the initial position, while gripping
the starting end 42 of the stretch wrap 40, such that the stretch
wrap is pulled behind the free end 22 of the cable 24. As used
herein, the term "behind" is intended to mean that the stretch wrap
40 is disposed between the fee end 22 of the cable 24 and the
remaining length of the cable wound on the spool 26. More
particularly, the stretch wrap 40 is disposed between the free end
22 of the cable 24 and the outermost windings of the cable already
wound onto the spool 26 between the outer flanges 28.
[0037] FIG. 7A is a front perspective view of the spooling machine
10 illustrating that the pulling clamp 32 of the stretch wrap
applicator 30 is next moved downwardly relative to the spool 26 of
wound cable 24. The pulling clamp 32 may be moved downwardly in any
suitable manner, such as mechanically, electrically or
pneumatically. As shown herein, the pulling clamp 32 is mounted on
an angled rail 36 that is movably attached to the housing 34 of the
stretch wrap applicator 30 with a predetermined angle such that the
pulling clamp 32 and the starting end 42 of the stretch wrap 40 are
moved in a generally tangential direction relative to the periphery
of the cable 24 wound on the spool 26. In this manner, the stretch
wrap 40 is pulled downwardly relative to the spool 26 so as to be
pinched within a nip defined between the outermost windings of the
cable 24 already wound on the spool and the free end 22 of the
cable.
[0038] FIG. 7B is a rear perspective view of the spooling machine
10 illustrating the stretch wrap 40 disposed between the outermost
windings of the cable 24 and the free end 22 of the cable.
[0039] FIG. 8 is a front perspective view of the spooling machine
10 illustrating the stretch wrap 40 released by the pulling clamp
32 of the stretch wrap applicator 30 with the stretch wrap in
contact with at least a portion of the outermost windings of the
cable 24 wound on the spool 26. In this manner, the stretch wrap 40
disposed between the outermost windings of the cable 24 and the
free end 22 of the cable is next wrapped around the spool 26 of
wound cable as the remaining length of the free end of the cable is
being wound onto the spool.
[0040] FIG. 9 shows the free end 22 of the cable 24 is cut so that
the free end of the cable will be disposed beneath the stretch wrap
40 as the stretch wrap continues to be wrapped around the spool 26
of wound cable.
[0041] If desired, the stretch wrap 40 may be moved across the
spool 26 of wound cable 24 between the outer flanges 28 of the
spool so that the entire width of cable on the spool is covered by
the stretch wrap as the stretch wrap is wrapped around the spool.
FIG. 10 shows the stretch wrap 40 optionally being moved across the
width of the spool 26 to traverse the cable 24 wound on the spool
and thereby wrap the entire spool of wound cable with the stretch
wrap. FIG. 11 is a rear perspective view showing the entire width
of the cable 24 wound onto the spool 26 and optionally wrapped with
the stretch wrap 40.
[0042] FIG. 12 is a rear perspective view showing a stretch wrap
cutter 38 of the stretch wrap applicator 30 located in a position
to cut a finishing end 44 of the stretch wrap 40. The stretch wrap
cutter 38 may be any suitable means for cutting stretch wrap 40,
such as a blade, hot knife or the like. As shown herein, stretch
wrap cutter 38 is a heated cutter configured for and operative to
cut the finishing end 44 of the stretch wrap 40 at a desired
position so that the pulling clamp 32 of the stretch wrap
applicator 30 can subsequently grip another starting end 42 of the
stretch wrap 40 for wrapping a length of cable 24 wound onto a
subsequent spool 26.
[0043] FIG. 13 is a rear perspective view showing the finishing end
44 of the stretch wrap 40 cut and wrapped around the cable 24 wound
onto the spool 26. As a result, the finished cable spool (i.e. a
desired length of the cable 24 wound onto spool 26 and wrapped with
stretch wrap 40) is available to be removed from the spooling
machine 10 and transferred to a shipping container, such as a
corrugated box, or to a pallet for being transported with other
finished cable spools to an end user, such as an installer of
communications cable. Once the finished cable spool is removed from
the spooling machine 10, a subsequent spool 26 may be positioned on
the spooling head 20 so as to receive the free end 22 of the cable
24 to be wrapped onto the spool and wrapped with the stretch wrap
40, as previously described herein, and form another finished cable
spool.
[0044] FIG. 14 is a rear perspective view illustrating the stretch
wrap applicator 30 being moved transversely, in the manner
previously described, to a location adjacent the other of the two
spooling heads 20 of the spooling machine 10. As such, the same
stretch wrap applicator 30 is utilized to apply a relatively thin
layer of the stretch wrap 40 onto a length of cable 24 wound onto a
spool 26 at the other spooling head 20 of the spooling machine 10.
In this manner, there is no unnecessary duplication of components
of the stretch wrap applicator 30, thereby reducing the overall
cost, complexity and maintenance of the stretch wrap applicator and
the spooling machine 10. Furthermore, the other spooling head 20
may be utilized to form the subsequent spool 26 of wound cable 24
while the stretch wrap applicator 30 is being utilized to apply
(i.e., wrap) the first spool of wound cable with stretch wrap
40.
[0045] A stretch wrap applicator 60 according to another exemplary
embodiment of the present invention is shown in FIGS. 15-26. The
stretch wrap applicator 60 comprises a pair of servo-driven coil
movers 62 operable for moving a length of cable 24 wound onto a
spool 26 at a spooling head 20 of the spooling machine 10.
Hereinafter, the cable 24 wound onto the spool 26 is also referred
to as coil 24, 26.
[0046] FIG. 15 shows the coil 24, 26 gripped between the pair of
coil movers 62 just before the length of cable 24 is cut. The coil
movers 62 are positioned so as to grip the coil 24, 26 as the cable
24 is cut to create a free end of the cable. If necessary, the coil
24, 26 is rotated up to about one-quarter turn to locate the free
end of the cable in an optimum position. When the coil 24, 26 is
properly positioned, the coil movers 62 move the coil downwards
with the coil supported by a pair of side guides 64.
[0047] As shown in FIG. 16, when the coil 24, 26 is low enough for
a pair of side grippers 66 to clear the side guides 64, the side
grippers are engaged with the coil in a suitable manner, such as by
a pneumatic cylinder. A position sensor, for example a Hall Effect
sensor, may be utilized to identify that the side grippers 66 are
in the correct position as they move upwards to engage the coil 24,
26. Ideally, the movement of the side grippers 66 into engagement
with the coil 24, 26 should be accomplished while the coil is being
moved downwards without an additional interruption (stoppage) of
the movement of the coil.
[0048] As shown in FIG. 17, when the center 25 of the coil 24, 26
clears the side guides 64, a cable end holder 70 is engaged to hold
the free end of the cable 24. A position sensor, for example a Hall
Effect sensor, may be utilized to indicate when the cable end
holder 70 is in the proper position to engage the free end of the
cable 24. Ideally, the movement of the cable end holder 70 into
engagement with the free end of the cable 24 should be accomplished
while the coil 24, 26 is being moved downwards without an
additional interruption (stoppage) of the movement of the coil.
[0049] FIG. 18 shows the coil 24, 26 in the stretch wrap position
to begin the stretch wrap process. The starting end of the stretch
wrap 40 is held by a gripper 72. The stretch wrap 40 mounted on an
orbiter 80 (e.g. rotary arm) is rotated around the coil 24, 26, for
example in a counter-clockwise direction. The orbiter 80 may
comprise a belt drive 82, a suitable motor, for example a 3 KW AC
motor, and a pulse encoder in a known manner. The tension on the
stretch wrap 40 may be controlled by a manually adjusted mechanical
brake roller 88. In addition, a guide 68 (see e.g., FIG. 19) may be
provided for guiding the stretch wrap 40 between the orbiter 80 and
the gripper 72. For purposes of convenience, the guide 68 may be
disposed, for example, on the orbiter 80.
[0050] As shown in FIG. 19, just before the first revolution of the
stretch wrap 40 on the orbiter 80 is completed, the gripper 72
tilts downward. As a result, the starting end of the stretch wrap
40 is secured by the next layer of the stretch wrap. As shown in
FIG. 20, when the starting end of the stretch wrap 40 is secured
under the next layer of the stretch wrap, the gripper 72 releases
the plastic stretch wrap and an air blower is used to force the
free end of the cable 24 under the next layer of the stretch
wrap.
[0051] As shown in FIG. 21, when the stretch wrap 40 is on its
final revolution, the open gripper 72 moves back upwards and the
roll of stretch wrap 40 is stopped in its home position. As shown
in FIG. 22, the finishing end of the stretch wrap 40 is secured by
the gripper 72 and the stretch wrap is cut in a suitable manner,
for example by a blade, a hot knife or a hot wire driven in a
suitable manner, for example by a pneumatic cylinder. The loose
finishing end of the stretch wrap 40 is forced against the coil 24,
26 by an air blower.
[0052] FIG. 23 shows that the cable end holder 70 can then release
the free end of the cable 24. An upper coil mover spade 74 is moved
into position by a pneumatic cylinder to ensure that it is clear
for the coil movers 62 to move upwards relative to the coil 24, 26.
At this point in time, the coil 24, 26 wrapped in stretch wrap 40
is held in place by the side grippers 66 alone, which are not
visible in FIG. 23.
[0053] FIG. 24 illustrates that when a side gripper valve is
operated to release the pressure of the side grippers 66 on the
stretch wrapped coil 24, 26, the side grippers are not yet opened.
The coil 24, 26 is then pushed out from between the side grippers
66 by suitable means, for example a pusher operated by a pneumatic
cylinder. As a result, the stretch wrapped coil 24, 26 slides down
a guide 89 onto a driven conveyor system 90, as shown in FIG. 25
and FIG. 26. The pusher then moves back inwards and the side
grippers 66 are opened so that the lower coil mover 62 can be moved
upwards to repeat the cycle. FIG. 25 and FIG. 26 illustrate how the
stretch wrapped coil 24, 26 is moved along the driven conveyor
system 90 and dropped into a container, such as a corrugated box
(not shown) or onto a pallet for storage and transport, in a manner
similar to that previously described with respect to stretch wrap
applicator 30.
[0054] The foregoing has described exemplary embodiments of a
stretch wrap applicator for a spooling machine having one or more
spooling heads for winding a desired length of cable onto a spool
and wrapping the finished cable spool with stretch wrap to secure
the free end of the cable on the spool. The exemplary embodiments
of the present invention described herein are shown and/or
illustrated in the accompanying drawing figures. In an exemplary
embodiment, a single stretch wrap applicator is transversely
moveable on the spooling machine relative to two spooling heads so
that the stretch wrap applicator is usable with both of the
spooling heads. The stretch wrap applicator includes a pulling
clamp for gripping and pulling a starting end of the stretch wrap
into a nip between the outermost windings of the cable already
wound onto the spool and the free end of the cable. The stretch
wrap is then wrapped around the spool of wound cable and the free
end of the cable is cut and secured beneath the stretch wrap. In
another exemplary embodiment, a stretch wrap applicator includes a
pair of coil movers that position a coil of cable wound on a spool
relative to the starting end of stretch wrap. The free end of the
cable is secured while the stretch wrap mounted on a rotary arm is
wrapped around the coil with the free end of the cable secured
beneath the stretch wrap. The coil is then released and pushed onto
a driven conveyor system to be delivered to a container or a pallet
for storage and transport.
* * * * *