Patent Application
20250128909
The present disclosure relates to apparatus and methods for winding coils of flexible material, such as cable (including network cable and fiber optic cable), wire (including THHN wire, NM-B wire, grounding wire, UF-B wire), tubing, hose, or rope. More particularly, this application can relate to apparatus and methods for winding coils of flexible material that are dispensed through a payout tube.
U.S. Pat. No. 2,634,922 to Taylor describes the winding of flexible material (such as wire) around a mandrel in a figure-eight pattern such that a package of material is obtained having a plurality of layers surrounding a central core space. By rotating the mandrel and by controllably moving a traverse that guides the wire laterally relative to mandrel, the layers of the figure-eight pattern are provided with aligned holes (cumulatively a “payout hole”) such that the inner end of the flexible material (wire) may be drawn out through the payout hole. The resulting wound coil is a short hollow cylinder. When a package of flexible material (wire) is wound in this manner, the flexible material (wire) may be unwound through the payout hole without rotating the package, without imparting a rotation in the flexible material (wire) around its axis (i.e., twisting), and without kinking. This provides a major advantage to the users of the flexible material (wire). Coils wound in this manner and capable of being dispensed from the inside-out without twists, tangles, snags or overruns are known in the art as REELEX-type coils. REELEX is a trademark of Reelex Packaging Solutions, Inc. of Patterson, NY.
Over the past fifty-plus years, improvements have been made to the original invention described in U.S. Pat. No. 2,634,922. For example, U.S. Pat. No. 5,470,026 to Kotzur describes systems for controlling the reciprocating movement of the traverse with respect to the rotation of the mandrel in order to wind the flexible material (wire) on the mandrel to form a radial payout hole having a substantially constant diameter. A payout tube defining a tubular pathway and flange may be inserted in the coil with the pathway extending through the payout hole, and the end of the wire making up the coil fed through the payout tube for ease in dispensing the wire. In addition, as a terminal part of the winding process, a layer of plastic film may be located over the wound coil to prevent uncoiling.
Over the past fifty-plus years, an increasing number of different types of flexible material (wire) with different characteristics are being wound using the systems and methods described in U.S. Pat. No. 2,635,922 and the subsequent improvements. The figure-eight type winding has been used for twisted-pair type cable (e.g., Category 5, Category 6 and the like), drop cable, fiber-optic cable, electrical building wire (THHN), etc.
While numerous improvements have been made to REELEX-type winding systems, further improvements that lead to additional throughput in the winding apparatus are desired. More specifically, the existing REELEX-type winding systems are limited in the number of coils of a specified linear feet that can be coiled in a given period of time. This limitation is due to inherent constraints in the winding process, which include the time required to wind the coil, the time required to apply the plastic film, the time required to insert the payout tube into the payout hole in the coil, the time required to remove the prepared coil from the winding apparatus, and then the time required to prepare the winding apparatus for winding a subsequent coil.
This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.
An embodiment of an apparatus for winding coils of flexible material includes a support frame and a vertical plate assembly (or platform) that rotates relative to the support frame. A first rotary shaft is mechanically coupled or fixed to the plate assembly. Two mandrel parts are mounted on respective second and third rotary shafts that are mounted to the plate assembly. The rotational axes of the second and third rotary shafts are parallel to one another and parallel to, but laterally offset from, the rotational axis of the first rotary shaft. The two mandrel parts each define at least part of respective winding spools.
In embodiments, the apparatus can further include means for coordinating rotation of the plate assembly about the first rotational axis with counter rotation of the first and second mandrel parts about the second and third rotational axes, respectively. The means for coordinating the rotation of the plate assembly with the counter rotation of the first and second mandrel parts can be configured to operate during transition operations performed between winding operations that employ the first and second mandrel parts in an ordered sequence one after the other. The transition operations can also be performed between packaging operations that employ the first and second mandrel parts in an opposite ordered sequence one after the other. In this case, the apparatus can be operated in a repetitive cycle of winding operations concurrent with packaging operations, with transition operations between the cycles of concurrent winding and packaging operations. In this repetitive cycle, one mandrel part is used for winding operations while the other mandrel part is used for packaging operations. The concurrent winding and packing operations are followed by the transition operations that involve the rotation of the plate assembly coordinated with the counter rotation of the first and second mandrel parts. After the transition operations, the mandrel parts switch their use roles with respect to the concurrent winding and packaging operations.
In embodiment, the means for coordinating rotation of the plate assembly with counter rotation of the first and second mandrel parts can include a gear mechanism. The gear mechanism can be configured to rotate the second rotary shaft and the mandrel part mounted thereon as well as rotate the third rotary shaft and the mandrel part mounted thereon in a coordinated manner (e.g., in a common rotational direction opposite the rotational direction of the plate assembly) with respect to rotation of the first rotary shaft and the plate assembly.
In other embodiments, the means for coordinating rotation of the plate assembly with counter rotation of the first and second mandrel parts can employ electronic controller that control motors that drive the rotation of the plate assembly and the counter rotation of the first and second mandrel parts.
In embodiments, the second rotary shaft and the mandrel part mounted thereon can be configured to rotate independently from the first rotary shaft and the plate assembly with the plate assembly in one or more fixed rotational positions. The third rotary shaft and the mandrel part mounted thereon can also be configured to rotate independently from the first rotary shaft and the plate assembly with the plate assembly in one or more fixed rotational positions.
In embodiments, the first rotary shaft can be operably coupled to a first drive mechanism (e.g., motor/gear box) that is operated to drive rotation of the first rotary shaft and the plate assembly.
In embodiments, a cutter system can be mounted on the plate assembly and centrally disposed between the two mandrel parts. The cutter mechanism can have first and second slots and corresponding cutting elements. The first slot and corresponding cutting element can be configured to cut material that is wound onto one mandrel part (first mandrel part) while the material is captured by the other mandrel part (second mandrel part). The second slots and corresponding cutting element can be configured to cut material that is wound onto the second mandrel part while the material is captured by the first mandrel part.
In embodiments, a second drive mechanism (e.g., motor/gear box) can be coupled to a winding mandrel interface. The winding mandrel interface can be configured to be selectively engaged and coupled to either one of the two mandrel parts. When the winding mandrel interface is engaged and coupled to the respective mandrel part, both the winding mandrel interface and the mandrel part form a winding spool used for winding operations. Furthermore, when the winding mandrel interface is engaged and coupled to the respective mandrel part, the winding mandrel interface can be adapted to automatically configure the respective mandrel part/winding mandrel to rotate independently from the plate assembly (and the first rotary shaft). In this configuration, the second drive mechanism can be operated to drive rotation of the winding mandrel interface and the mandrel part of the resulting winding spool during the winding operations. In embodiments, the engagement and coupling of the winding mandrel interface to the respective mandrel part can involve linear motion toward the plate assembly, and the disengagement and decoupling of the winding mandrel interface from the respective mandrel part can involve linear motion away from the plate assembly.
In embodiments, the second drive mechanism and the winding mandrel interface can be operated to selectively engage and couple to one of the two mandrel parts and then rotate the resulting winding spool as part of winding operations carried out in an alternating manner. These alternating operations can be carried out in a controlled manner when the respective mandrel parts are disposed at a predefined first position (or winding station) relative to the support frame. In embodiments, the first position (winding station) can be set by the rotational position of the plate assembly.
In embodiments, the system can also include a traverse mechanism supported by the frame and configured to guide material onto the winding spool at the first position during the winding operations.
In embodiments, the system can also include a movable plastic film applicator supported by the frame and configured to apply plastic film onto material wound onto the winding spool at the first position (winding station) during the winding operations.
In embodiments, each mandrel part can include a support collar mounted on a spline shaft. The support collar can be adapted to support a plurality of displaceable mandrel segments that move axially and radially relative to the support collar to define a collapsed configuration and an expanded configuration. The mandrel segments can move axially and radially relative to the support collar from the collapsed configuration to the expanded configuration, or vice versa. The support collar can also be adapted to support an annular flange that extends radially outward away from the support collar and surrounds the mandrel segments. The spline shaft can include a plate interface at one end and a keyed interface at the opposite end. The plate interface can be configured to interface to the plate assembly. The keyed interface can be configured to interface to the winding mandrel interface or the packaging mandrel interface, respectively. The support collar can define slots or bores or channels that are adapted to receive corresponding sections of the mandrel segments for sliding movement therein, which guides the axial and radial movement of the mandrel segments relative to the support collar to define the collapsed configuration and the expanded configuration. In embodiments, the mandrel segments can be biased by springs or other resilient elements into the collapsed configuration. For example, the springs or other resilient elements can be disposed in the bores or slots defined by the support collar.
In embodiments, each mandrel part can also employ a segment locking system that retains the mandrel segments of the mandrel part in the radially expanded configuration until the segment locking system is released. In the expanded configuration of the mandrel segments, the coil of material wound on the mandrel segments (possibly with plastic film applied thereto) is supported and held in position on by the mandrel segments such that the coil cannot be easily removed from the mandrel segments. The keyed interface of the respective mandrel part can be configured to engage and mate to corresponding keyed interfaces of the winding mandrel interface and the packaging mandrel interface. In this engaged configuration, the matching keyed interfaces can operate to configure the spline shaft of the respective mandrel part such that it rotates independently from the plate assembly and drives the rotation of the spline shaft of the respective mandrel part. The keyed interface of the respective mandrel part can also cooperate with the keyed interface of the packaging mandrel interface to release the segment locking system of the respective mandrel part. The respective mandrel parts can also include a material capture mechanism that retains or captures a free end of material (formed by cutting the material).
In embodiments, parallel portions of two or more mandrel segments of the respective mandrel parts can be shorter in length (cutoff) relative to the parallel portions of other mandrel segments. The shorter-length mandrel segments can be configured to expose a material capture mechanism that is adapted to capture material therein. In embodiments, the material capture mechanism can be adapted to i) automatically capture material during transition operations (and while cutting material during the transition operations) and ii) retain the free end of material formed by the cutting operations during the remainder of transition operations following the cut and subsequent winding operations.
In embodiments, the second drive mechanism can be adapted to drive rotation of the winding mandrel interface and the respective mandrel part that form the winding spool relative to plate assembly while the plate assembly is held in a fixed position (e.g., winding station). This configuration allows material to be wound onto the winding spool in a pattern controlled by the operation of the traverse mechanism during the winding operations. After the winding operations are complete, the winding mandrel interface (and the second drive mechanism coupled thereto) can be disengaged and decoupled from the respective mandrel part. In embodiments, the disengagement and decoupling of the winding mandrel interface from the respective mandrel part involves linear motion away from the plate assembly.
During transition operations, the first drive mechanism can be operated to rotate the first rotary shaft and the plate assembly together with second and third rotary shafts and the two mandrel parts mounted thereon about the first rotational axis. In embodiments, this rotation is configured to rotate the two mandrel parts one-hundred and eighty degrees about the first rotational axis such that two mandrel parts exchange rotational position with one another. This rotates the mandrel part located at the first position (winding station) to a predefined second position (or packaging station) dictated by one hundred and eighty degrees rotation of the plate assembly, and simultaneously rotates the mandrel part located at the second position (packaging station) to the first position (winding station).
In embodiments, during the transition operations, the plastic film applicator can be configured to move along a track (which preferably follows a curved path) and apply plastic film to material wound on the respective mandrel part as the mandrel part rotates from the first location to the second location.
In embodiments, a third drive mechanism (e.g., robot system) can be coupled to a packaging mandrel interface. The packaging mandrel interface can be configured to selectively engage and couple to either one of the two mandrel parts. The packaging mandrel interface can be adapted to engage and couple to a respective mandrel part (in a locked expanded configuration) that holds a wound coil of material (possibly wrapped with plastic film) at the second position (packaging station). In embodiments, the engagement and coupling of the packaging mandrel interface to the respective mandrel part involves linear motion toward the plate assembly.
In embodiments, the packaging mandrel interface can include a spline shaft with a plurality of grabber elements that pivot radially relative to the spline shaft to define an expanded configuration and a collapsed configuration. The grabber elements can pivot relative to the spline shaft from the expanded configuration to the collapsed configuration, or vice versa. The spline shaft can also be adapted to support an annular flange that extends radially outward away from the spline shaft with slots that receive portions of the grabber elements and accommodate the pivoting movement of the grabber elements. The grabber elements can be configured to extend radially relative to the spline shift through alternating void spaces between the mandrel segments of the respective mandrel part in their collapsed configuration (e.g., to engage the inside surface of a wound coil). The spline shaft can include a drive interface at one end and a keyed interface at the opposite end. When the packaging mandrel interface is engaged and coupled to the respective mandrel part, the mandrel segments of the respective mandrel part can be configured in their locked expanded configuration. In this engaged configuration, the coil of material wound on the mandrel segments (possibly with plastic film applied thereto) is supported and held in position by the mandrel segments of the mandrel part. Furthermore, the matching keyed interfaces of the respective mandrel part and the packaging mandrel interface can operate to configure the spline shaft of the respective mandrel part such that it rotates independently from the plate assembly and drive the rotation of the spline shaft of the respective mandrel part (e.g., for orientation of the payout hole of the wound coil).
Furthermore, the packaging mandrel interface can include a payout tube support, which is configured to support a payout tube that is positioned within a payout hole of a coil wound on a mandrel part coupled thereto. Such support can be configured to limit movement of the payout tube when material is grabbed and pulled through the payout tube by an external robotic system as described herein.
Furthermore, the packaging mandrel interface can include a part that is adapted to release the segment locking system of the respective which permits the mandrel segments of the respective mandrel part to automatically move from the expanded configuration to a collapsed configuration. Before, after or during the movement of the mandrel segments into their collapsed configuration, the grabber elements of the packaging mandrel interface can pivot into their expanded configuration to extend radially through alternating void spaces between the mandrel segments of the respective mandrel part and contact the inner surface of the wound coil. With the mandrel segments of the respective mandrel in their collapsed configuration and the grabber elements of the packaging mandrel interface in their expanded configuration, the wound coil of material (possibly wrapped with plastic film) can be supported solely by the grabber elements of the packaging mandrel interface. The packaging mandrel interface can then be disengaged and decoupled from the respective mandrel part with the wound coil of material (possibly wrapped with plastic film) supported by the grabber elements of the packaging mandrel interface. In embodiments, the disengagement and decoupling of the packaging mandrel interface from the respective mandrel part involves linear motion away from the plate assembly. The wound coil of material (possibly wrapped with plastic film) supported by the grabber elements of the packaging mandrel interface can be moved or transported by the third drive mechanism coupled thereto, and can be released and removed from the packaging mandrel interface by pivoting motion of the grabber elements of the packaging mandrel interface into their collapsed configuration.
In embodiments, the wound coil of material (possibly wrapped with plastic film) on the respective mandrel part has a payout hole between the windings of the wound material. The third drive mechanism and the packaging mandrel interface can be adapted to rotate or otherwise orient the wound coil of material (possibly wrapped with plastic film) on the respective mandrel part at the second location (packaging station) into an orientation where the payout hole is positioned in an upright (or other known) configuration for receiving a payout tube. In embodiments, the payout tube can be placed in the payout hole by a robotic payout tube handling system or human operator.
In embodiments, the robotic payout tube handling system receives payout tubes from a supply of payout tubes. The system may include a payout tube supply station including a storage hopper for receiving payout tubes, a conveyor that transfers payout tubes from the storage hopper to a feed bowl or small hopper, and a linearizing feed path from the feed bowl or small hopper to a pickup station. The robotic payout tube handling system is configured to acquire a payout tube from the pickup station and install the payout tube into the payout hole in the wound coil at the second location (packaging station). The robotic payout tube handling system can be further configured to engage and draw a free end of material from the wound coil through the installed payout tube, and support the payout tube against the wound coil while the material is drawn out through the payout tube at the second location (packaging station).
One or more controllers can be coupled to the various drive mechanisms, the cutter system, the robotic system(s) and various position sensors (such as shaft encoders, contact sensors, proximity sensors, etc.). A user interface (such as a touch screen display) can be operably coupled to the controller(s) to control and coordinate the execution of the operations performed by the system.
In an embodiment, the system may be operated in repetitive cycles of winding operations concurrent with packaging operations, with transition operations between the cycles of concurrent winding and packaging operations. The winding operations are performed with a respective mandrel part positioned in the first position (winding station). The packaging operations are performed with a respective mandrel part positioned in the second position (packaging station). The transition operations rotate the two mandrel parts one-hundred and eighty degrees about the first rotational axis of the plate assembly such that two mandrel parts exchange rotational position with one another. This rotates the mandrel part located at the first position (winding station) to the second position (packaging station), and simultaneously rotates the mandrel part located at the second position (packaging station) to the first position (winding station).
In embodiments, the second drive mechanism can be configured to drive rotation of respective mandrel parts (and the second and third rotary shafts) in a first rotational direction (counter-clockwise) about the corresponding second and third rotational axes during the winding operations. Furthermore, the first drive mechanism can be configured to drive rotation of the two mandrel parts (with the second and third rotary shafts) together with the plate assembly in a second rotational direction (e.g., clockwise) about the first rotational axis during the transition operations. The second rotational direction is opposite the first rotational direction.
In the winding operations, the winding mandrel interface engages and couples to the respective mandrel part located at the first position (winding station), and the winding spool formed by the winding mandrel interface and the mandrel part at the first position (winding station) is rotated by operation of the second drive mechanism with the plate assembly in a fixed position. This rotation winds a coil of material onto the winding spool with the material guided onto the winding spool by the traverse mechanism. The second drive mechanism operates to rotate the winding spool formed on the first rotary shaft to form a coil of material of a defined length of wire. The defined length can be set by user input on the user interface. After winding is complete, the winding mandrel interface disengages and decouples from the winding spool. For purposes of explanation, the initial winding can be performed with the first rotary shaft and corresponding mandrel part engaged and coupled to the winding mandrel interface coupled to the second drive mechanism, and the second rotation drive shaft and corresponding mandrel part located at the second position (packaging station). However, it should be appreciated that each of the first and second rotary shafts and corresponding mandrel parts are the same and either may be a starting point for the operations described.
In the transition operations, the first drive mechanism rotates the first rotary shaft to rotate the plate assembly by one-hundred and eighty degrees and exchange the positions of the two mandrel parts (and the first and second rotary shafts) between the first position (winding station) and the second position (packaging station). During this rotation, the plastic film applicator moves on its track to apply film onto the wound coil as the plate assembly is rotated and the wound coil is moved and rotated on the plate assembly. Furthermore, during this rotation, material attached to the wound coil at the first position (winding station) and supplied by the traverse mechanism is pulled or otherwise placed into the path of the cutter system and also pulled or otherwise placed into the path of the wire capture mechanism of the other mandrel part (which is moving from the packaging station). The material in the path of the wire capture mechanism of the other mandrel part is automatically captured by the wire capture mechanism during the rotation, and then the material in the path of the cutter system is cut during the rotation. The cutting of the material releases the wound coil from the supply of wire provided by the traverse mechanism, and leaves a free end of material captured by the other mandrel part (which is moving to the winding station). The winding operations of the next coil employs the winding spool formed from the other mandrel part at the winding station. The winding operations occur simultaneously with the packaging operations.
In the packaging operations, the packaging mandrel interface engages and couples to the respective mandrel part located at the second position (packaging station). The third drive mechanism is operated to rotate the wound coil (with plastic film) such that the payout hole of the coil is in a known orientation. With the payout hole positioned at the known orientation, the payout tube handling system inserts the payout tube in the payout hole and pulls out an inner end of material through the payout tube. The packaging mandrel interface can include grabber elements that engage the interior of the wound coil and support the resultant wound coil with plastic film and payout tube. The packaging mandrel interface then disengages and decouples from the mandrel part at the packaging station, removing the resultant wound coil of material (wrapped with plastic film with payout tube) from the mandrel part and leaving behind the empty mandrel part (in its collapsed configuration). The resultant wound coil of material (wrapped with plastic film with payout tube) supported by the grabber elements of the packaging mandrel interface can be moved or transported by the third drive mechanism coupled thereto. For example, the resultant wound coil of material can be transported to another location for storage or further packaging. The packaging operations of the next coil employs the winding spool formed from the other mandrel part at the packaging station. The packaging operations (or portions thereof) can occur simultaneously with the winding operations.
In other embodiments, the system can be used to wind a coil of material without a payout tube. In this embodiment, the packaging operations performed at the second location (packaging station) can involve configuring the grabber elements of the packaging mandrel interface to engage the interior of the wound coil and support the resultant wound coil with plastic film. The packaging mandrel interface then disengages and decouples from the mandrel part at the packaging station, removing the resultant wound coil of material (wrapped with plastic film) from the mandrel part and leaving behind the empty mandrel part (in its collapsed configuration). The resultant wound coil of material (wrapped with plastic film) supported by the grabber elements of the packaging mandrel interface can be moved or transported by the third drive mechanism coupled thereto. For example, the resultant wound coil of material can be transported to another location for storage or further packaging. The packaging operations of the next coil employs the winding spool formed from the other mandrel part at the packaging station. The packaging operations (or portions thereof) can occur simultaneously with the winding operations as described herein.
In other embodiments, the mandrel parts of the system can be winding spools that are detachably mounted on (and dismounted from) the second and third rotary shafts. Cycles of concurrent winding and packaging operations with transition operations therebetween can be performed with the winding spools as follows. During packaging operations at the packaging station, a winding spool with a coil of material wound thereon (possibly with a plastic film applied thereto and optional payout tube) can be dismounted from one of the second and third rotary shafts and replaced with an empty winding spool mounted thereon. These packaging operations can be performed manually by a human operator or by a robotic system. Concurrent with these packaging operations at the packaging station, an empty winding spool mounted on the other of the second and third rotary shafts (in the previous packaging operations) can be operated to wind a coil of material thereon at the winding station. During the transition operations, the plate assembly rotates and the winding spool with a coil of wound material thereon at the winding station moves from the winding station to the packaging station and the empty winding spool at the packaging station moves from the packaging station to the winding station. During this rotation, the plastic film applicator can move on its track to apply a plastic film onto the wound coil as the plate assembly is rotated and the wound coil is moved and rotated on the plate assembly. Furthermore, during this rotation, material attached to the wound coil at the winding station and supplied by the traverse mechanism can be pulled or otherwise placed into the path of the cutter system and also pulled or otherwise placed into the path of a material capture mechanism of the empty winding spool (which is moving from the packaging station). The material in the path of the material capture mechanism of the empty winding spool can be automatically captured by the mechanism during the rotation, and then the material in the path of the cutter system is cut during the rotation. The cutting of the material releases the wound coil from the supply of material provided by the traverse mechanism, and leaves a free end of material captured by the empty winding spool (which is moving to the winding station).
During the transition operations, the rotation of the first rotary shaft and the plate assembly mounted thereon can be coordinated with counter rotation of the second and third rotary shafts and the winding spools mounted thereon.
In embodiments, the means for coordinating rotation of the first rotary shaft and the plate assembly with counter rotation of the second and third rotary shafts and the winding spools mounted thereon can include a gear mechanism. The gear mechanism can be configured to rotate the second rotary shaft and the winding spool mounted thereon as well as rotate the third rotary shaft and the winding spool mounted thereon in a coordinated manner (e.g., in a common rotational direction opposite the rotational direction of the plate assembly) with respect to rotation of the first rotary shaft and the plate assembly.
In other embodiments, the means for coordinating rotation of the first rotary shaft and the plate assembly mounted thereon with counter rotation of the second and third rotary shafts and the winding spools mounted thereon can employ electronic controller that control motors that drive the rotation of the first rotary shaft and plate assembly and the counter rotation of the second and third rotary shafts and the winding spools.
In embodiments, the flexible material wound into the coil can be cable (including network cable and fiber optic cable), wire (including THHN wire, NM-B wire, grounding wire, UF-B wire), tubing, hose, rope, or other filamentary material.
The cycles of concurrent winding and packaging operations with transition operations therebetween may be continuously and autonomously repeated. The packaging operations may be timed to occur in the same or reduced amount of time as the winding operations such that the winding operations can occur substantially continuously without waiting for the packaging operations to complete. The system includes a winding station and a packaging station for concurrent winding and packing operations with minimal downtime, which can provide significant advantages and efficiencies for winding coils, and particularly for REELEX-type systems, though not limited thereto.
In order to describe the manner in which the above-recited and other features of the disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings may be schematic or exaggerated representations of concepts, at least some of the drawings may be drawn to scale. Understanding that the drawings depict some example embodiments, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
The first rotary shaft 107 can be operably coupled to a bearing support 113 and a first drive mechanism 115 (e.g., motor/gear box) that are disposed on the back side of the window 101a and plate assembly 105 as best shown in
In embodiments, the plate assembly 105 can include a circular plate 105a with two elongated support elements 105b, 105c mounted on opposite sides of the plate 105a as best shown in
In embodiments, the planetary gear mechanism includes two planet gears 115a, 115b that mesh with a fixed ring gear 115c that is rigidly mounted to the window 101a as best shown in
In embodiments, the clutch 117a can be configured in its disengaged configuration such that the mandrel part 109a and the second rotary shaft 111a can rotate independently from the plate assembly 105 (and the first rotary shaft 107) with the platform assembly 105 in a fixed rotational position. Similarly, the clutch 117b can be configured in its disengaged configuration such that the mandrel part 105b and the third rotary shaft 111b can rotate independently from the plate assembly 105 (and the first rotary shaft 107) with the platform assembly 105 in the fixed rotational position. Furthermore, the clutch 117a and the clutch 117b can be configured concurrently in their engaged configuration while the first drive mechanism 115 drives rotation of the first rotary shaft 107 and the plate assembly 105 in a particular rotational direction (e.g., counter-clockwise when viewed from the back side of the plate assembly and clockwise when viewed from the front side of the plate assembly) relative to the window 101a/frame 101. The rotation of the plate assembly 105 relative to the window 101a/frame 101 drives counter rotation of the planetary gears 115a, 115b relative to the fixed ringed gear 115c together with the corresponding rotary shafts 111a, 111b and the mandrel parts 109a, 109b in the rotational direction opposite that of the first rotary shaft 107 and the plate assembly 105 (e.g., clockwise when viewed from the back side of the plate assembly and counter-clockwise when viewed from the front side of the plate assembly).
A cutter system 118 can be mounted on the plate assembly 105 (i.e., on the support element 105b) in a position centrally disposed between the two mandrel parts 109a, 109b as best shown in
A second drive mechanism (e.g., motor/gear box) 119 can be coupled to a winding mandrel interface 121 as best shown in
In embodiments, the second drive mechanism 119 and the winding mandrel interface 121 can be operated to selectively engage and couple to the two mandrel parts (109a, 109b), and then rotate the resulting winding spools formed by the two mandrel parts in an alternating manner. These alternating operations can be carried out in a controlled manner when the respective mandrel parts (109a or 109b) are disposed at a predefined first position (or winding station). In embodiments, the first position (winding station) can be set by the rotational position of the plate assembly 105 during the winding operation. In embodiments, the winding station corresponds to the 3 o'clock rotational position of the plate assembly 105 in the frame window 101a.
The apparatus can also include a traverse mechanism 125 supported by the frame 101 as best shown in
The apparatus can also include a movable plastic film applicator 127 supported by the frame 101 and configured to apply plastic film onto material wound onto the winding spool at the first position (winding station) during the winding operation as best shown in
In embodiments shown in
In other embodiments, the servo-motor 187 can be mounted directly on the applicator 127 and configured to drive movement of servo-motor 187 together with applicator 127 along the track 129. For example, the servo-motor 187 could be connected to track 129 by one or more cogged wheels that engage with corresponding geometry of the track 129.
Turning back to
In embodiments, the support collar 131 can include a first part that extends beyond the annular flange 137 toward the keyed interface 141 and a second part that extends beyond the annular flange 137 toward the plate interface 139 (and back cover 132b). The first part can have a tapered frustoconical outer surface with slots 143 that are aligned with internal bores 145 formed by the second part of the support collar 131 and an outer casing 132a as best shown in
In embodiments, each mandrel part 109a, 109b can employ a segment locking system that retains the mandrel segments 135 of the respective mandrel part in the radially expanded configuration until the locking system is released. The expanded configuration of the mandrel segments is best shown in
In embodiments, the segment locking system of the respective mandrel parts (109a or 109b) can include a rotating hub 191 internal to the respective mandrel part (109a or 109b) with a set of ball detents 191a mounted thereon as shown in
In embodiments, the parallel portions of two or more mandrel segments 135 of the respective mandrel parts 109a, 109b can be shorter in length (cutoff) relative to the parallel portions of the other mandrel segments 135 as best shown in
In embodiments, the winding mandrel interface 121 can include a support collar 151 mounted on a solid spline shaft 153 as best shown in
In embodiments, the support collar 151 can include a first part that extends beyond the annular flange 157 toward the keyed interface 159 and a second part that extends beyond the annular flange 157 toward the drive coupling end 161 (and cover 162b). The first part has a tapered frustoconical outer surface with slots 163 that are aligned with internal bores 165 formed by the second part of the support collar 151 and an outer casing 162a as best shown in
When the winding mandrel interface 121 is initially engaged and coupled to the respective mandrel part (109a or 109b), both the mandrel segments 135 of the respective mandrel part and the coupling segments 155 of the winding mandrel interface 121 can be configured in their corresponding collapsed configurations, and the coupling segments 135 of the winding mandrel interface 121 contact and mate to the shorter (or cut-off) parallel mandrel segments 135 of the respective mandrel part (for example, through contact via a pin-hole mating interface) with the collar 151 of the winding mandrel interface 121 contacting the longer parallel mandrel segments 135 of the respective mandrel part. In this configuration, further axial movement of the winding mandrel interface 121 toward the respective mandrel part (109a or 109b) and the resulting further engagement of the winding mandrel interface 121 and the respective mandrel part (109a or 109b) imparts axial and radial movement of the mandrel segments 135 into their expanded configuration together with axial and radial movement of the coupling segments 155 into their corresponding expanded configuration. When the mandrel segments 135 are moved into their expanded configuration, the segment locking system of the respective mandrel part (109a or 109b) can be automatically activated to lock the mandrel segments 135 in their expanded configuration (until being unlocked, for example, by the operation of the packaging mandrel interface 171). In this engaged configuration, the keyed interface 141 of the respective mandrel part (109a or 109b) and the keyed interface 159 of the winding mandrel interface 121 can cooperate to configure the spline shaft 133 of the respective mandrel part (109a or 109b) such that it rotates independently from the plate assembly 105 and drives the rotation of the spline shaft 133 of the respective mandrel part (109a or 109b) (for example, for winding of material onto the coil). In the expanded configuration of the mandrel segments 135, the coil of material that is wound on the mandrel segments 135 is supported and held in position on by the mandrel segments 135 such that the coil cannot be easily removed from the mandrel segments 135.
In embodiments, with the winding mandrel interface 121 mated to the respective mandrel part (109a or 109b), these two components together form a winding spool. The mandrel segments 125 of the mandrel part (109a or 109b) and the coupling segments of the winding mandrel interface 121 define a central mandrel of the winding spool. The flange 137 of the mandrel part (109a or 109b) and the flange 157 of the winding mandrel interface 121 define opposed end forms of the winding spool. The second drive mechanism 119 can be adapted to drive rotation of the winding mandrel interface 121 and the respective mandrel part (109a or 109b) that form the winding spool relative to plate assembly 105 while the plate assembly 105 is held in a fixed position. This configuration allows material to be wound onto the winding spool in a pattern controlled by the operation of the traverse mechanism 125 during the winding operations. After the winding operations are complete, the winding mandrel interface 121 (and the second drive mechanism 119 coupled thereto) can be disengaged and decoupled from the respective mandrel part (109a or 109b). In embodiments, the disengagement and decoupling of the winding mandrel interface 121 from the respective mandrel part involves linear motion away from the plate assembly 105.
During transition operations, the first drive mechanism 115 can be operated to rotate the first rotary shaft 107 and the plate assembly 105 together with second and third rotary shafts 111a, 111b and the two mandrel parts 109a, 109b mounted thereon about the first rotational axis. In embodiments, this rotation is configured to rotate the two mandrel parts (109a or 109b) one hundred and eighty degrees about the first rotational axis such that two mandrel parts exchange rotational position with one another. This rotates the mandrel part located at the first position (winding station) to a predefined second position (or packaging station) dictated by the one hundred and eighty degree rotation of the plate assembly 105, and simultaneously rotates the mandrel part located at the second position (packaging station) to the first position (winding station). In embodiments, if one considers the ring gear 115c as a clock face, the first position (winding station) can be defined at the 3 o'clock rotational position, and the second position (packaging station) can be defined at the 9 o'clock rotational position. Alternatively, other suitable rotational positions of the plate assembly 105 can be used for the winding station and packaging station, respectively.
In embodiments, during the transition operations, the plastic film applicator 127 can be configured to move along a curved track 129 and apply plastic film (e.g., stretch wrap) to material wound on the respective mandrel part (109a or 109b) as the mandrel part rotates from the first location to the second location.
A third drive mechanism (e.g., robot system) 180 can be coupled to a packaging mandrel interface 171 as shown in
In embodiments illustrated in
When the keyed interface 173b of the packaging mandrel interface 171 is initially engaged and coupled to the keyed interface 141 of a respective mandrel part (109a or 109b), the mandrel segments 135 of the respective mandrel part can be configured in their locked expanded configuration In this configuration, the coil of material wound on the mandrel segments 135 (and with plastic film applied thereto) is supported and held in position by the mandrel segments 135 of the mandrel part. Furthermore, when the keyed interface 173b of the packaging mandrel interface 171 is engaged and coupled to the keyed interface 141 of the respective mandrel part (109a or 109b), the keyed interfaces 141, 173b can cooperate to automatically configure the spline shaft 133 of the respective mandrel part such that it rotates independently from the plate assembly 105 and drives the rotation of the spline shaft 133 of the respective mandrel part (e.g., for setting the orientation of the payout hole of the wound coil).
The packaging mandrel interface 171 can further include a payout tube support 199, which is configured to support a payout tube that is positioned within a payout hole of a coil wound on a respective mandrel part (109a or 109b) coupled thereto. Such support can be configured to limit movement of the payout tube when material is grabbed and pulled through the payout tube by an external robotic system as described herein.
Furthermore, the respective mandrel parts (109a, 109b) and the packaging mandrel interface 171 can include cooperating features or parts that are adapted to release the segment locking system of the respective mandrel parts when the keyed interface 173b of the packaging mandrel interface 171 is engaged and coupled to the keyed interface 141 of the respective mandrel part (109a or 109b). The release of the segment locking system of the mandrel part permits the mandrel segments 135 of the mandrel part to automatically move from the expanded configuration to the collapsed configuration as shown in
In embodiments where the segment locking system of the respective mandrel parts includes a rotating hub 191 with a set of ball detents 191a as shown in
Before, after or during the movement of the mandrel segments 135 into their collapsed configuration (
In embodiments, the wound coil of material (wrapped with plastic film) on the respective mandrel part has a payout hole between the windings of the wound material. The third drive mechanism 180 and the packaging mandrel interface 171 can be adapted to rotate or otherwise orient the wound coil of material (wrapped with plastic film) on the coupled mandrel part at the second location (packaging station) into an orientation where the payout hole is positioned in an upright (or other known) configuration for receiving a payout tube. In embodiments, the payout tube can be placed in the payout hole by a robotic payout tube handling system 201 as shown in
The packaging mandrel interface 171 can further include a payout tube support 199, which is configured to support the payout tube placed om the payout hole of a coil wound on a respective mandrel part (109a or 109b) coupled thereto. Such support can be configured to limit movement of the payout tube when material is grabbed and pulled through the payout tube by the robotic payout tube handling system 201.
In embodiments, the robotic payout tube handling system 201 receives payout tubes from a supply of payout tubes. The system may include a payout tube supply station 203 including a storage hopper 205 for receiving payout tubes, a conveyor 207 that transfers payout tubes from the storage hopper 205 to a feed bowl or small hopper 209, and a linearizing feed path 211 from the bowl or hopper 209 to a pickup station 211. The bowl or hopper 209 can be configured to position the payout tubes in a predefined orientation on the linearizing feed path 211 for delivery to the pickup station in the predefined orientation. The robotic payout tube handling system 201 can be configured to acquire a payout tube from the pickup station 211 and install the payout tube into the payout hole in the wound coil at the second location (packaging station). The robotic payout tube handling system 201 can be further configured to engage and draw a free end of material from the wound coil through the installed payout tube, and support the payout tube against the wound coil while the material is drawn out through the payout tube at the second location (packaging station).
One or more controllers can be coupled to the various drive mechanisms (115, 119), the cutter system 118, the robotic system(s) 180, 201, the components of the payout tube supply station 203, and various position sensors (such as shaft encoders, contact sensors, proximity sensors, etc.). A user interface (such as a touch screen display) can be operably coupled to the controller(s) to control and coordinate the execution of the operations performed by the system.
In an embodiment, the system may be operated in a repetitive 4-part cycle of winding operations concurrent with packaging operations, with transition operations between the cycles of concurrent winding and packaging operations as summarized in Table 1 below:
The winding operations of parts 1 and 3 are performed with a respective mandrel part (109a or 109b) positioned in the first position (winding station). The packaging operations of parts 1 and 3 are performed with a respective mandrel part (109a or 109b) positioned in the second position (packaging station). The transition operations of parts 2 and 4 rotate the two mandrel parts 109a, 109b one-hundred and eighty degrees about the first rotational axis of the first rotary shaft 107 and the plate assembly 105 such that two mandrel parts 109a, 109b exchange rotational position with one another. This rotates the mandrel part located at the first position (winding station) to the second position (packaging station), and simultaneously rotates the mandrel part located at the second position (packaging station) to the first position (winding station).
In embodiments, the second drive mechanism 119 can be configured to drive rotation of the second rotary shaft 111a and the mandrel part 109a in a first rotational direction (counter-clockwise) about the corresponding second rotational axis during the winding operations when the second drive mechanism 119 is operably coupled to the mandrel part 109a. Similarly, the second drive mechanism 119 can be configured to drive rotation of the third rotary shaft 111b and the mandrel part 109b in the first rotational direction (counter-clockwise) about the corresponding third rotational axis during the winding operations when the second drive mechanism 119 is operably coupled to the mandrel part 109b.
During the transition operations, the first drive mechanism 115 can be configured to rotate the first rotary shaft 107 and the plate assembly 105 in a second rotational direction (clockwise direction), and the planetary gear arrangement (gears 115a, 115b, 115c) can be configured to drive counter rotation of the second rotary shaft 111a and the mandrel part 109a mounted thereon as well as counter rotation of the third rotary shaft 111b and the mandrel part 109b mounted thereon in a coordinated manner (e.g., both in the first (counter-clockwise) rotational direction opposite the second (clockwise) rotational direction of the plate assembly) during the rotation of the first rotary shaft 107 and the plate assembly 105.
In other embodiments, during the transition operations, the rotation of the second rotary shaft 111a and the mandrel part 109a mounted thereon can be coordinated with the rotation of the third rotary shaft 111b and the mandrel part 109b mounted thereon (e.g., both in a first (counter-clockwise) rotational direction opposite the second (clockwise) during rotation of the first rotary shaft 107 and the plate assembly 105 by electronic control of the motors that drive rotation of first rotary shaft 107 and the plate assembly 105 and the counter rotation of the second rotary shaft 111a/mandrel 109a and the third rotary shaft 111b/mandrel 109b.
In the winding operations, the winding mandrel interface 121 engages and couples to the respective mandrel part (109a or 109b) located at the first position (winding station), and the winding spool formed by the winding mandrel interface and the mandrel part at the first position (winding station) is rotated by operation of the second drive mechanism 119 with the plate assembly 105 in a fixed position corresponding to the first position (winding station). This rotation winds a coil of material onto the winding spool with the material guided onto the winding spool by the traverse mechanism 125 as shown in
In the transition operations, the first drive mechanism 115 rotates the first rotary shaft 107 to rotate the plate assembly 105 and the mandrel parts 109a, 109b mounted thereon by one-hundred and eight degrees and exchange the positions of the two mandrel parts (and the first and second rotary shafts) between the winding station and packaging station as shown in
In the packaging operations, the packaging mandrel interface 171 engages and couples to the respective mandrel part (109a or 109b) located at the second position (packaging station). The third drive mechanism 180 is operated to rotate the wound coil (with plastic film) such that the payout hole of the coil is in a known orientation. With the payout hole positioned at the known orientation, the payout tube handling system 201 inserts the payout tube in the payout hole and pulls out an inner end of material through the payout tube. The payout tube support 199 of the packaging mandrel interface 171 can be configured to support the payout tube in the payout hole when material is grabbed and pulled through the payout tube by the payout tube handling system 201. The packaging mandrel interface 171 can include grabber elements 175 that engages the interior of the wound coil and supports the resultant wound coil with plastic film and payout tube. The packaging mandrel interface 171 then disengages and decouples from the mandrel part at the packaging station, removing the resultant wound coil of material (wrapped with plastic film with payout tube) from the mandrel part and leaving behind the empty mandrel part (in its collapsed configuration). The resultant wound coil of material (wrapped with plastic film with payout tube) supported by the grabber elements 175 of the packaging mandrel interface 171 can be moved or transported by the third drive mechanism 180 coupled thereto. For example, the resultant wound coil of material can be transported to another location for storage or further packaging. The packaging operations of the next coil employs the winding spool formed from the other mandrel part at the packaging station. The packaging operations (or portions thereof) can occur simultaneously with the winding operations.
In other embodiments, the system can be used to wind a coil of material without a payout tube. In this embodiment, the packaging operations performed at the second location (packaging station) can involve configuring the grabber elements of the packaging mandrel interface to engage the interior of the wound coil and support the resultant wound coil with plastic film. The packaging mandrel interface then disengages and decouples from the mandrel part at the packaging station, removing the resultant wound coil of material (wrapped with plastic film) from the mandrel part and leaving behind the empty mandrel part (in its collapsed configuration). The resultant wound coil of material (wrapped with plastic film) supported by the grabber elements of the packaging mandrel interface can be moved or transported by the third drive mechanism coupled thereto. For example, the resultant wound coil of material can be transported to another location for storage or further packaging. The packaging operations of the next coil employs the winding spool formed from the other mandrel part at the packaging station. The packaging operations (or portions thereof) can occur simultaneously with the winding operations as described herein.
In yet other embodiments, the mandrel parts of the system can be winding spools (two shown as 109a′, 109b′) that are detachably mounted on (and dismounted from) the rotary shafts 111a, 111b of the system as shown in
During the transition operations, the rotation of the first rotary shaft and the plate assembly mounted thereon can be coordinated with counter rotation of the second and third rotary shafts and the winding spools mounted thereon.
In embodiments, the means for coordinating rotation of the first rotary shaft and the plate assembly with counter rotation of the second and third rotary shafts and the winding spools mounted thereon can include a gear mechanism. The gear mechanism can be configured to rotate the second rotary shaft and the winding spool mounted thereon as well as rotate the third rotary shaft and the winding spool mounted thereon in a coordinated manner (e.g., in a common rotational direction opposite the rotational direction of the plate assembly) with respect to rotation of the first rotary shaft and the plate assembly.
In other embodiments, the means for coordinating rotation of the first rotary shaft and the plate assembly mounted thereon with counter rotation of the second and third rotary shafts and the winding spools mounted thereon can employ electronic controller that control motors that drive the rotation of the first rotary shaft and plate assembly and the counter rotation of the second and third rotary shafts and the winding spools.
The cycles of concurrent winding and packaging operations with transition operations therebetween as described herein can be performed continuously and autonomously repeated. The packaging operations may be timed to occur in the same or reduced amount of time as the winding operations such that the winding operations can occur substantially continuously without waiting for the packaging operations to complete. The apparatus can provide for cycles of concurrent winding and packing operations with minimal downtime, which can provide significant advantages and efficiencies for winding coils, and particularly for REELEX-type systems, though not limited thereto.
In embodiments, the flexible material wound into the coil can be cable (including network cable and fiber optic cable), wire (including THHN wire, NM-B wire, grounding wire, UF-B wire), tubing, hose, rope, or other filamentary material.
Enumerated clauses are now provided for the purpose of illustrative some possible embodiments that may be provided in accordance with the disclosure. The clause sets provided below are for illustration and not to be construed as limiting, exclusive or exhaustive. Features recited in one clause set may be utilized and incorporated into one or more of the other clause sets.
Embodiments disclosed herein may provide an apparatus for winding flexible material that includes:
Embodiments disclosed herein may provide an apparatus for winding flexible material that includes:
Embodiments disclosed herein may provide an apparatus for winding flexible material that includes:
Embodiments disclosed herein may provide an apparatus for winding flexible material that includes:
Embodiments disclosed herein may provide a method for winding flexible material that includes:
There have been described and illustrated herein several embodiments of apparatus, systems, and methods of winding coils of flexible material. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.
The present disclosure claims priority from U.S. Provisional Appl. No. 63/592,516, filed Oct. 23, 2023, entitled “APPARATUS, METHODS, AND SYSTEMS FOR WINDING COILS OF FLEXIBLE MATERIAL,” herein incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63592516 | Oct 2023 | US |
